Tesla Model S: HV Junction Box - Cover - 1st Generation (Remove and Replace)
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
minimum rating of class 00 (500V) must be worn any time a high
voltage cable is handled. Refer to Tech Note TN-15-92-003, "High
Voltage Awareness Care Points" for additional safety information.
Removal
- Disconnect 12V and HV power:
- Rear wheel drive (RWD): Refer to procedure.
- Dual Motor: Refer to procedure.
- Remove the 2nd row cushion frame (refer to procedure).
Warning: Proper personal protective equipment (PPE) and
insulating HV gloves with a minimum rating of class 00 (500V) must
be worn while performing the remainder of this procedure.
Warning: Ensure that the multimeter and leads are capable
of handling at least 500V.
- Remove the bolts (x6) that secure the HV junction box cover
(torque 5 Nm). Remove the cover.
- Use a multimeter to check voltages across the HV cables and to
ground:
- B+ to ground
- B- to ground
- B+ to B-
Warning: If any voltage reading is more than 10V, the high
voltage contactors are not fully opened. Due to the risk of
electrocution, contact Service Engineering before performing
any further work.
Installation
Installation procedure is the reverse of removal.
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Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
SEE MORE:
Backup
Connect a laptop with Toolbox 2.0 or later to the vehicle.
Select Panels > Gateway and Center Display > MCU
Cloner.
Click MCU Backup to backup the MCU files.
If the backup is successful, click MCU Disable to disable the
MCU. If the backup was not successful, co
Removal
Open vehicle door, ensuring good access.
Carefully release clip (x1) securing top of flap seal to door.
Caution: Take care not to damage component(s).
Note: Components have been removed in this graphic
to aid clarity.
Caution: