2024 Tesla Cybertruck Ancillary Cover Rework TSB

Understanding the 2024 Tesla Cybertruck Ancillary Cover Rework

Tesla has issued Service Bulletin SB-24-16-007 for certain 2024 Cybertruck vehicles. This bulletin outlines a necessary rework involving the Tesla Cybertruck ancillary cover to prevent potential damage to the Ancillary Bay Mid Voltage (MV) Header. The repair ensures the long-term integrity of the electrical system by mitigating impact risks.

Symptoms and Condition

The condition identified by Tesla is a potential for the ancillary cover to cause damage to, or impact, the Ancillary Bay Mid Voltage (MV) Header. This is a preventative measure to avoid issues with the vehicle's electrical system. The rework is primarily performed if the ancillary cover has been removed for other service procedures, ensuring proper reinstallation and protection.

Important Warnings and Notes for Owners

Tesla emphasizes several critical points regarding this service bulletin:

• Professional Service Required: "These instructions should only be performed by trained professionals."
• No Prior Inspection Needed: "If this bulletin is applicable to the vehicle, perform the correction without any need for inspection."
• Labor Time Considerations: "The following steps should be performed if the ancillary cover has already been removed, and before reinstallation. Therefore, the labor time does not account for the time it takes to remove the ancillary cover or any prerequisite steps."
• Safety During Foam Cutting: "To reduce the risk of personal injury, use cut resistant gloves and appropriate eye protection while performing this step."
• Foam Placement Caution: "Avoid positioning the foam in the red area marked in Figure 3 to avoid contact with the MV power connector lever."
• Zip Tie Installation Caution: "Make sure the zip tie is fully zipped. Accidental, even partial, opening of the connector may cause the DCDC enable line to open."
• Skip If Already Installed: "Skip this step if a zip tie is already installed." (Referring to the PCS MV connector zip tie)

Repair Procedure Summary

The repair outlined in Service Bulletin SB-24-16-007 involves two main steps to address the Tesla Cybertruck ancillary cover issue:

1. Foam Block Installation:

   • A piece of Adhesive Backed Neoprene Foam 3/8" (part number 2069255-00-A) is cut to a specific size of 1 inch by 2 inches using a retractable blade knife.
   • This foam block is then installed onto the inside of the ancillary cover. Technicians must carefully position the foam to avoid contact with the MV power connector lever, as detailed in the service bulletin's diagrams.

2. PCS MV Connector Securing:

   • With the Power Conversion System (PCS) MV connector fully connected, a zip tie is installed around the connector body and its release lever.
   • This zip tie prevents accidental opening of the connector, which could otherwise lead to the DCDC enable line opening. Technicians are instructed to ensure the zip tie is fully secured and to skip this step if a zip tie is already present.

These steps are designed to prevent the ancillary cover from impacting the Ancillary Bay Mid Voltage (MV) Header and to ensure the secure connection of the PCS MV connector.

Required Tools or Parts

To perform this rework, technicians will require the following:

• Part Number: 2069255-00-A - Adhesive Backed Neoprene Foam 3/8" (Quantity: 1)
• Shop Supply: Retractable Blade Knife

The bulletin notes that part number 2069255-00-A was current at the time of publication, advising technicians to use the revision listed or later, as specified in the Parts Catalog.

Owner Action

If you own a 2024 Tesla Cybertruck, this service bulletin addresses a preventative measure rather than a direct symptom you would notice. Tesla is not notifying consumers directly for this type of bulletin. It is recommended to check with your Tesla Service Center or through your vehicle's service history to confirm if this bulletin applies to your vehicle and if the rework has been performed. The correction involves a minimal labor time of 0.06 hours for the foam block installation (correction code S022416007).

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NHTSA ID: 11006909