Tesla Model X: HV Harness - Rapid Splitter to FJB (Replace)

Installation

Caution: Replace all Patchbolt(s).

1. Install protective caps over both HV cables to protect the terminals and seals when pulling the harness through the channel.
2. Secure the new HV harness to the nylon fish tape tool using string or fishing line and, from the rear RH wheel arch, gently pull the front of the nylon fish tape tool through the channel towards the rear of the vehicle and retrieve the HV harness.
3. Apply P-80 emulsion to the connector seals on the HV cables before securing the HV cables to the FJB.

   Caution: Do not apply P-80 emulsion to the HV terminals.

   

4. Inspect the retaining springs before installing the locking collars. Ensure that the retaining spring is seated correctly.

   
   Retaining spring seated correctly
    
   Retaining spring seated incorrectly
   
   Retaining spring seated incorrectly

5. Use the installation tool to install both locking collars in the Rapid splitter.

   Note: Install both locking collars into the Rapid Mate before installing either of the HV cables.

    

6. Use the flare nut crowfoot wrench at 90 degrees from the torque wrench when torquing the collar (torque 35 Nm). Caution: If the flare nut crowfoot wrench is not 90 degrees from the torque wrench, it can damage the special tool and/or the rapid splitter.

    

7. After inserting the new HV cables into the Rapid Splitter, perform pull test to ensure that the cables are correctly installed. Note: The HV cables must be pulled with a force of 150N.
8. Install the O-rings on the HV cables:
   1. Place the seal installation tool over the terminal.
   2. Apply P-80 emulsion to the seal installation tool.
   3. Push the O-ring along the seal installation tool until it slides onto the HV cable.

      

   4. Remove the seal installation tool from the HV cable.
   5. Perform steps a-d on the other HV cable.