SB-10057893-4439
SB-15-17-002

Tesla Motors, Inc.

March 11, 2015

Service Bulletin

Replace Prototype 12V Fuse Box Bracket
Classification

Campaign Bulletin

Section/Group

17 - Electrical

Country/Region

United States

Year

2014

Model

Model S

Version

Dual Motor

Bulletin Classification: This campaign bulletin addresses a known non-safety-related condition and provides
recommended technical diagnosis and repair procedures. Apply this procedure to all vehicles in the affected VIN range
listed. These instructions assume knowledge of motor vehicle and high voltage electrical component repairs, and should
only be executed by trained professionals. Tesla Motors assumes no liability for injury or property damage due to a failure
to properly follow these instructions or repairs attempted by unqualified individuals.

Condition
Some early dual motor vehicles were manufactured with a prototype 12V fuse box bracket.

Correction
Replace the prototype 12V fuse box bracket with the production-level part.

Required Part(s): Part Number
1031595-00-D
1054163-00-A
2007207
1005805-00-A
1009420-00-A
1015209-00-A
1053847-00-A

1015197-00-A
1032246-00-A

Description
BRACKET, 12V BATTERY FUSEBOX, DUAL MOTOR
BRACKET, 12V FUSEBOX SUPPORT, LOWER
NUT HF M6-1.00[8]ZnAl
BLT HEX FL M8-1.25X25 8.8 -M-ZnAl
BLT HF M6-1.00x20[8.8]ZnAlW
HT 156-00071
TAPE,PET CLOTH,ACRYLIC,19MM W,150C,BK

Quantity
1
1
2
2
2
1
As required

If necessary:
6.7MM CABLE TIE CLIP
BUTYL FOIL, 40x40, 1 MM THICK

1 or 2
1

Shop supplies:
Alcohol wipes
These part numbers were current at the time of publication. Use the revisions listed or later,
unless otherwise specified in the Parts Manual.
Correction Description

Correction

Time

SB-15-17-002 Not Applicable

S011517002

0.00

Replace Prototype 12V Fuse Box Bracket Secured By Push Pin Or 2 Bolts

S021517002

0.50

Replace Prototype 12V Fuse Box Bracket Secured By Screw Through Bulkhead

S031517002

0.80

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Procedure
1. Disconnect 12V power (refer to Service Manual procedure 17010200).
2. Remove the pollen filter rear housing:
a. Release the 2 barrel clips that secure the HV harness to the bulkhead.
b. Loosen the top RH nut that secures the pollen filter rear housing to the bulkhead (torque 6 Nm) (Figure 1).
NOTE: It is not necessary to completely remove the nut; the tab on the housing is notched.

Figure 1
c.

Remove the remaining 3 nuts that secure the pollen filter rear housing to the bulkhead (torque 6 Nm) (Figure 2).

NOTE: The 2 lower nuts also secure the HVAC intake drain diverter.

HVAC intake
drain diverter

Figure 2
d. Remove the pollen filter rear housing and HVAC intake drain diverter.

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3. Remove the 2 bolts that secure the fuse box cover (Figure 3). Remove the fuse box cover.

Figure 3
4. Remove the nut that secures the battery positive terminal to the rear of the fuse box (Figure 4).

Figure 4
5. Remove the nut that secures 12V power supply for the DCDC converter (Figure 5).

Figure 5
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6. Remove the nut that secures the fuse box to the bracket (Figure 6).

Figure 6
7. Gently lift the fuse box up and remove the floating stud (Figure 7). Set the stud aside.

Figure 7
8. Remove and discard the 2 bolts that secure the front of the fuse box bracket to the shock tower (Figure 8).

Figure 8
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9. Bend the front of the bracket towards the bulkhead (Figure 9).
NOTE: It is okay to damage the bracket; it will be discarded later in the procedure.

Figure 9
10. Remove the 2 fir tree clips that secure the 12V harnesses to the bracket (Figure 10).
NOTE: The 12V harnesses can be secured to the bracket in multiple ways. Figure 10 shows one example. Remove the fir
tree clips as necessary.

Figure 10

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11. Inspect how the bracket is secured to the vehicle.
x
x
x

If the bracket is secured to the bulkhead by a push pin (Figure 11), remove and discard the push pin, remove and
discard the bracket, and then skip to step 21.
If the bracket is a 1-piece design and is secured to the vehicle by 2 vertical bolts (Figure 12), remove and discard
the bolts, remove and discard the bracket, and then skip to step 21.
If the bracket is secured to the bulkhead by a nut and a screw (Figure 13), continue to the next step in this
procedure.
Screw through
bulkhead

Push pin

2 vertical
bolts
Figure 11

Figure 12

Figure 13

12. Using needle nose pliers, grip the unthreaded tip of the screw and rotate it clockwise until it is flush with the threaded
nut on the bracket (Figure 14).
CAUTION: Do not grip the threads on the screw with the pliers. This could damage the threads on the screw, making
it difficult to back out from the threaded nut on the bracket.
CAUTION: Rotate the screw clockwise.

Figure 14

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13. From behind the bracket, continue rotating the screw clockwise (Figure 15) until it the bracket is free. Remove and
discard the bracket.

Figure 15
14. From inside the vehicle, remove the RH closeout extension (refer to Service Manual procedure 15191102).
15. Remove the RH footwell cover (refer to Service Manual procedure 14055402).
16. Fold the passenger footwell carpet away from the bulkhead.
17. Insert a magnetic pickup tool in front of the NVH padding to retrieve the screw from the bulkhead (Figure 16). Discard
the screw.
TIP: It might be helpful to gently tap the tip of the screw towards the bulkhead from inside the frunk so that it is more
accessible from inside the vehicle.
NOTE: If necessary, remove the nut that secures the bracket for the footwell stud.
CAUTION: Do not allow the screw to drop beneath the NVH material inside the vehicle.
Screw located here

Remove this
nut if necessary
Insert magnetic
pickup tool here

Figure 16

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18. Reposition the passenger footwell carpet.
19. Reinstall the RH footwell cover.
20. Reinstall the RH closeout extension.
21. From inside the frunk, clean the area around the hole in the bulkhead with an alcohol wipe. Allow the alcohol to dry
before continuing to the next step.
NOTE: Some vehicles that had a 1-piece fuse box bracket (Figure 12) might not have a hole through the bulkhead. If the
vehicle does not have an exposed hole through the bulkhead, skip to step 23.
22. Apply a butyl foil patch over the hole in the bulkhead (Figure 17).
NOTE: Smooth out the entire surface of the butyl patch to ensure that it is fully adhered to the bulkhead and that all of the
air bubbles have been removed.

Figure 17
23. Install the 2 bolts that secure the new lower bracket (torque 19 Nm) (Figure 18).

Figure 18

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24. Install the 2 fir tree clips to the lower bracket (Figure 19).
NOTE: If either fir tree clip is damaged, replace with 1015197-00-A. Trim the excess portion of the cable ties.

Figure 19
25. Ensure that the harness for the forward junction box (FJB) branch is routed behind the motor mount.
26. Loosely install a nut on each of the 2 horizontal studs on the lower bracket.
27. Lower the new upper bracket onto the lower bracket so that the notches on the bottom of the upper bracket are lined
up with the horizontal studs on the top of the lower bracket.
TIP: It might be helpful to remove the shock tower cover and press against the lower bracket with a pry bar to keep the
lower bracket in place.
28. Tighten the 2 nuts that secure the upper bracket to the lower bracket (torque 6 Nm) (Figure 20).

Figure 20 (Components removed for clarity)

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29. Install the 2 bolts that secure the upper bracket to the shock tower (torque 6 Nm) (Figure 21).

Figure 21
30. Inspect the 12V harness and ensure that there are no exposed or damaged wires. Wrap every part of the harness that
could potentially rub against the fuse box bracket with the provided abrasion tape.
CAUTION: Failure to wrap the harness with the provided abrasion tape could result in damage to the harness.
31. Insert the cable tie clip (1015209-00-A) into the 9 mm hole on the upper bracket shelf as shown (Figure 22).

Clip inserted
into 9 mm hole

Figure 22 (Cable tie and clip highlighted)

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32. Route the 12V harness over the shelf on the upper bracket and secure it with the cable tie (Figure 23).

Cable tie securing
12V harness

Figure 23
33. Ensure that the A/C lines do not rub against the upper bracket.
34. Insert the stud into the bottom of the fuse box (Figure 7) and set the fuse box on top of the upper bracket.
35. Reinstall the nut that secures the fuse box to the bracket (torque 6 Nm) (Figure 6).
36. Reinstall the nut that secures 12V power supply for the DCDC converter (torque 12.5 Nm) (Figure 5).
37. Reinstall the nut that secures the battery positive terminal to the rear of the fuse box (torque 12 Nm) (Figure 4).
38. Reinstall the 2 bolts that secure the fuse box cover (torque 3 Nm) (Figure 3).
39. Reinstall the pollen filter rear housing and HVAC intake drain diverter.
40. Connect 12V power (refer to Service Manual procedure 17010200).

Affected VIN(s)

Affected dual motor Model S vehicles built between approximately November 7, 2014 and
November 15, 2014.
NOTE: This is a simplified summary of the affected VIN list. Refer to the VIN/Bulletin Tracker or
Customer/Vehicle profile to determine applicability of this bulletin for a particular vehicle.

For feedback on the accuracy of this document, email [email protected].

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