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
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Note: This procedure describes how to remove and replace
the 40A Wall Connector handle and cable assembly. For instructions
on how to remove and replace the 80A Wall Connector handle and cable
assembly, refer to procedure 50022002 (refer to procedure).
Removal
Warning
The following collision avoidance features are designed
to increase the safety of you and your passengers:
Forward Collision Warning - provides visual and
audible warnings in situations when Model S detects
that there is a high risk of a frontal collision.
Automatic Emergency Braking - autom