Tesla Model S Owners & Service Manuals

Tesla Model S: HV Junction Box - Cover - 1st Generation (Remove and Replace)

Tesla Model S (2012-2024) Service Manual / High Voltage System / 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

  1. Disconnect 12V and HV power:
    • Rear wheel drive (RWD): Refer to procedure.
    • Dual Motor: Refer to procedure.
  2. 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.

  1. Remove the bolts (x6) that secure the HV junction box cover (torque 5 Nm). Remove the cover.

    HV Junction Box - Cover - 1st Generation (Remove and Replace)

  2. 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.

      HV Junction Box - Cover - 1st Generation (Remove and Replace)

      1 B+
      2 Ground
      3 B-

Installation

Installation procedure is the reverse of removal.

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