Tesla Model S High-Voltage System and Battery Drive Repair Guide

Fault Background

The Tesla Model S high-voltage system service manual has an ironclad rule throughout: perform the "vehicle electrical isolation procedure" before any high-voltage work, and any high-voltage disassembly comes with a high-voltage interlock warning. The four most practical sections on-site are: charge port (single-phase) removal/installation — inlet cover screws at 4 N·m, four mounting bolts tightened in sequence to 5 N·m, cable mounting bolts at 9 N·m, and after reassembly, use paint marks on the bolt heads as torque indicators; battery pack removal/installation — center bolts at 38 N·m, front subframe at 30 N·m, sill plates at 55 N·m, and immediately after removal, seal the high- and low-voltage ports with high-voltage caps (1038478-00-A) and pin voltage caps (1028325-00-A) (or 3M 2480S/471 tape if caps are unavailable); drive unit removal/installation — mount nuts at 90 N·m, motor-side mounts at 22 N·m, using the axle extractor and crane frame; and the wall-mounted high-power connector with stepped torques (1.1/2.3/3.4/17.2 N·m). This article compiles these four sections and safety procedures into an on-site guide.

High-Voltage Work Ironclad Rules

• Perform the "vehicle electrical isolation procedure" before any work (unified prerequisite step in the manual);
• Steps such as removing the high-voltage inlet cover carry high-voltage interlock warnings: if high-voltage components are disturbed without proper power-down, the vehicle will record a high-voltage interlock fault;
• Battery pack work also has an air spring Jack mode warning (vehicles with air suspension must enter Jack mode before lifting);
• Use a multimeter to check voltage at the high-voltage battery to confirm no residual high voltage before proceeding.

Charge Port (Single-Phase) Removal and Installation

Removal (average repair labor code 44012202):

1. Perform the vehicle electrical isolation procedure; remove the left trunk trim panel;
2. Remove screws from the high-voltage inlet cover and release clips (x2, torque 4 N·m), then remove the cover;
3. Remove and discard the bolts (x2) and all washers securing the high-voltage cable to the charge port; disconnect wiring connectors (x2);
4. Release the charge port clips from the body and set the high-voltage cable aside;
5. Remove and discard the bolts (x4) securing the charge port, then remove the charge port assembly.

Installation (reverse of removal, with additional specifics):

• Clean any adhesive residue from the high-voltage cable lugs and terminal surfaces;
• Insert the trim/bezel assembly back into the body opening, connect the halo wiring, and confirm an audible click;
• Loosely install the upper left bolt first, then the remaining x3, then tighten all 4 bolts in the shown sequence (5 N·m);
• Apply paint marks in a continuous motion across the bolt heads, washers, and charge port plastic surface to indicate proper tightening;
• Charge port cable clip lower nut 6 N·m (do not tighten the lock nut at this time); high-voltage cable mounting bolts x2 9 N·m; adjust the high-voltage cable to minimize port tension, then tighten the wire clip upper nut 5 N·m; ground bracket nut 6 N·m;
• Reinstall the claw drive cover, and attach safety labels before inserting the mobile connector.

Battery Pack Removal and Installation

• Special tool: Tesla 1028149-00-A high-voltage RAPIDMATE installation tool;
• Removal sequence: remove rear underbody panel → center bolts securing battery to body (x6, 38 N·m) → bolts securing high-voltage battery to front subframe (x4, 30 N·m) → bolts securing to left sill plate (x8, 55 N·m) → remaining mounting bolts (x6, 38 N·m);
• Before lowering, check voltage at the high-voltage battery with a multimeter;
• Port protection: insert high-voltage cap (1038478-00-A) and pin voltage cap (1028325-00-A) into high- and low-voltage battery ports; if caps are unavailable, cover with 3M 2480S masking tape (2-inch) or 3M 471 red PVC insulating tape (2-inch);
• Installation is the reverse of removal.

Drive Unit and Brake Disc

Drive unit removal: On both sides of the subframe, loosen upper link and universal joint mounting bolts → use axle extractor to remove half shafts from drive unit → secure crane frame bolts (x3) → loosen motor front/rear mounts and subframe mounting nuts (90 N·m) → loosen motor-to-motor-side mount bolts (x3, 22 N·m) → remove front mount bolts (90 N·m) → remove rear mount bolts (90 N·m) → carefully lift drive unit assembly, ensuring it clears the rear of the subframe.

Brake disc (front-left): Remove brake hose retaining clip → caliper mounting bolts (x2, 120 N·m), loosen caliper and tie aside → brake disc retaining screw (17 N·m) → remove brake disc; after installation in reverse, press brake pedal at least 5 times to seat brake pads against disc. Rear brake disc work also requires entering Jack mode first.

Wall-Mounted High-Power Connector (Removal and Installation)

Average repair labor code 50022002. Must turn off connector current at the circuit breaker, otherwise high voltage is lethal.

1. Housing mounting screws (x2, 1.1 N·m) → remove front cover, disconnect white retractable cable;
2. Loosen yellow-green ground wire screw (2.3 N·m);
3. Loosen red and black L1/L2 wire screws (x2, 17.2 N·m);
4. Loosen purple and yellow wire screws (x2, 1.1 N·m, hold green terminal board with finger);
5. Plastic clip mounting screws (x2, 3.4 N·m) → cut off spring clip with diagonal cutters → route cable through;
6. Installation: feed new cable active end through → install new spring clip with pliers → connect wires in reverse of removal and reinstall plastic clip → reconnect white retractable cable and front cover.

Safety Warnings

• This article is for technical reference; high-voltage system service must be performed by certified high-voltage technicians per OEM specifications. Unfamiliar readers are strictly prohibited from attempting any operation.
• The first step of all high-voltage work is always the "vehicle electrical isolation procedure"; violating high-voltage interlock warnings can cause serious injury or death.
• After battery pack removal, immediately seal high- and low-voltage ports with specified caps or 3M tape to prevent foreign objects and electric shock.
• Vehicles with air suspension must enter Jack mode before lifting, otherwise suspension damage or personal injury may occur.
• Single-use bolts and washers must be discarded and replaced; torque must be applied per the manual point-by-point and paint torque marks applied.

Repair Insights

The value of the Model S manual lies in three "closed loops." First, the isolation procedure loop — from charge port to battery pack, the first step of every procedure is the "vehicle electrical isolation procedure," with high-voltage interlock warnings everywhere: Tesla's logic is to make the system "not see" the high-voltage component before disassembly; skipping this step, the vehicle records an interlock fault, which is the least of the consequences. Second, the discardable parts loop — charge port high-voltage cable bolts, mounting bolts, and washers are all "remove and discard," combined with the "4 bolts tightened in sequence to 5 N·m + continuous paint mark" torque indicator system, making single-use fasteners and tightening verification standard practice. Third, the port protection loop — immediately after the battery pack is lowered, seal ports with 1038478-00-A/1028325-00-A caps or 3M tape; this is the most easily missed and most consequential step in battery removal. Memorize the torque table and you're set: charge port 4/5/6/9 N·m, battery 30/38/55 N·m, drive unit 22/90 N·m, brake disc 17/120 N·m, wall box 1.1/2.3/3.4/17.2 N·m.

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【This article is for reference only】