Tesla, Inc.
Service Bulletin

SB-18-16-008
December 28, 2023

Replace Rear Drive Unit HV Header and
Positive Contactor Bolts

R1

Classification

Section/Group

Mobile Service

Configuration

Campaign Bulletin

16 - HV Battery System

Cannot Perform

All

Model Year

Model

Country/Region

Build Location

2018

Model 3

United States, Canada

Fremont

The model(s) and model year(s) listed are a general approximation 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.

Campaign Bulletin: This campaign bulletin addresses a non-safety-related condition and provides recommended technical diagnosis
and repair procedures. Apply this procedure to the applicable vehicles.

This Service Document supersedes SB-18-16-008, dated September 13, 2018. This new revision, R1, updates the word
“penthouse” to “ancillary bay”. Each content change is marked by a vertical line in the left margin. Discard the previous
version and replace it with this one.

Condition
On certain Model 3 vehicles, the rear drive unit HV header bolts and the positive contactor bolt within the High Voltage
(HV) battery ancillary bay were insufficiently torqued to internal specifications during manufacturing.

Correction
Replace and properly torque the rear drive unit HV header bolts and the positive contactor bolt.
Correction Description

Correction

Time

SB-18-16-008 Not Applicable

S011816008

0.00

Replace And Torque RDU HV Header And Positive Contactor Bolts

S021816008

1.44

Part Number

Description

Quantity

Parts Required

1108958-00-A
1108907-00-A
1117669-00-A
1104475-00-C
1115916-00-A
2007104-00-B
1117252-00-A
1111033-00-D

SEAL,PROBE LID,HVBAT
BREATHER, NITTO Z-PLUG-S
BOLT,5-LOBE,M6X19,[109],ZNNI,MAT,PTP,SEAL
BOLTANDWSHR[DBL],M8X23,STL ZNFL,SDOG ADH
BOLT,TE,M6X14,[88],ZNNI,SEAL,SDOG
NUT HFPT M8X1.25 [10]-ZNNI
BOLT,HF,M12X40,STL [109],ZN,ADH,MAT
M3 2R BOLSTER CLIP

1
1
2
5
5
1
2
1

If Necessary

1467483-00-A

KIT, ANCILLARY BAY HV INSULATORS, M3

1

These part numbers were current at the time of publication. Use the revisions listed or later, unless
otherwise specified in the Parts Catalog.

Special Tools

SB-18-16-008 R1

1076927-00-A
1126496-00-B
1059330-00-B
1144879-00-A
1026636-00-A
1108272-00-B

Resistance meter, microohm, Hioki RM 3548
Wrench, Torque+Angle, 3/8" DR
Skt, 1/4in Dr, 5-Lobe Torx External
Kit, Encl Leak Test Adapters, HV Battery
Pack Enclosure Leak Tester, HV Battery
Cap, Logic Conn, Inv, 3DU
Page 1 of 4

1133603-00-A
1131071-00-A
1057602-00-A
1057603-00-A
1057607-00-A
1133768-00-A
1057606-00-A
1127845-00-A

Kit, HV Pyro-disconnect Replacement, BRP
Dummy Disconnect, Pyro, Safety
Ratchet, 1/4" Sq Dr, HV Insulated
Ext Bar, Wobble, 1/4" Dr, HV Insulated
Magnet, Flexible, HV Insulated, 18"
Socket, 1/4" Dr, Deep,10 mm,Thin Wall, Insul
Skt, 1/4" Sq Dr, 13mm, HV Insulated
Asy, Service Cover, Ancillary Bay, Model 3

Procedure
1. Remove the pyrotechnic battery disconnect (refer to Service Manual procedure 16300002).
2. Remove the insulator cap from the HV battery positive contactor output terminal bolt (Figure 1).

Figure 1
3. Remove and discard the bolt that attaches the HV battery positive contactor to the positive busbar (Figure 2).

Figure 2
4. Install a new bolt to attach the HV battery positive contactor onto the positive busbar, and then mark the bolt with a
paint pen after it is torqued (torque 5 Nm +60°) (Figure 2).

SB-18-16-008 R1

Page 2 of 4

5. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor
and the positive busbar (Figure 3).
NOTE: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a
Toolbox session, as appropriate.

Figure 3
6. Install the insulator cap onto the HV battery positive contactor output terminal bolt (Figure 1).
7. Raise the high voltage controller vertically, release the clips that attach the fuse access insulator to the ancillary bay,
and then remove the insulator from the ancillary bay (Figure 4).

Figure 4

SB-18-16-008 R1

Page 3 of 4

8. Remove and discard the bolts that attach the positive and negative busbars to the rear drive unit HV header (Figure
5).

Figure 5
9. Install new bolts to attach the positive and negative busbars to the rear drive unit HV header, and then mark the bolts
with a paint pen after they are torqued (torque 5 Nm +60°) (Figure 5).
10. Use the Hioki resistance meter to measure the resistance at the HV joint between the rear drive unit HV header and
the busbar at each bolt (Figure 6).
NOTE: The maximum acceptable resistance is 0.070 mΩ (70 μΩ). If the resistance is above this value, escalate a
Toolbox session, as appropriate.

Figure 6
11. Install the fuse access insulator, fasten the clips that attach the insulator to the ancillary bay, and then lower the high
voltage controller (Figure 4).
12. Install the pyrotechnic battery disconnect (refer to Service Manual procedure 16300002).

SB-18-16-008 R1

Page 4 of 4
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