2024 Tesla Cybertruck FFC Harness Misrouting TSB

Tesla has released Service Bulletin SB-24-17-004 for 2024 Cybertruck vehicles. This campaign bulletin addresses a non-safety-related condition where the backbone harness Flat Flex Cable (FFC) might be misrouted. A Tesla Cybertruck FFC misrouted condition can potentially lead to damage of the cable itself.

This bulletin provides recommended technical diagnosis and repair procedures to correct the issue. Owners of affected 2024 Tesla Cybertruck models should be aware of this potential problem and the outlined solution.

Symptoms

The primary symptom of this issue is potential damage to the backbone harness Flat Flex Cable (FFC). While the bulletin does not specify outward signs an owner might notice, the misrouting can lead to physical wear or stress on the cable. This could eventually impact the electrical system the FFC serves.

Important Warnings and Notes

Tesla has included several critical advisories within Service Bulletin SB-24-17-004 for technicians and owners:

• No Inspection Needed: If this bulletin is applicable to your vehicle, the correction procedure should be performed without any prior inspection.
• Thorough FFC Inspection: Technicians are cautioned to inspect both the topside and underside of the FFC for any abrasions or damage.
• Correct Foam Application: When applying 3M VHB foam, it is crucial not to wrap the cable. The foam should only be applied to the flat side of the cable. Wrapping the cable could cause damage due to excessive heat.
• Cable Positioning: Ensure the FFC is laid flat against the casting and is not twisted during routing.
• Sticker Placement: Any abrasion stickers should be applied directly to the vehicle, not to the FFC itself.
• Harness Guide Engagement: When securing the backbone harness and harness guide, confirm that the rib groove is correctly aligned and engaged. An audible click will confirm proper seating of the lower engagement point.

Repair Procedure Summary

The repair procedure outlined in Service Bulletin SB-24-17-004 involves several steps to address the Tesla Cybertruck FFC misrouted issue. The process begins with preparing the vehicle by opening all doors, lowering windows, and removing various interior trims, including the RH mid A-pillar, RH lower A-pillar, footwell cover, and RH center floor rail. The RH front and rear carpets are also moved to access the FFC.

Next, the technician inspects the front and rear passenger sections of the FFC for abrasions or damage. If severe damage, such as exposed inner wires, is found, the Mid Voltage (MV) backbone harness (part number 1682221-00-G) is replaced using correction code S022417004. If only abrasions to the outer cover are present, the FFC does not need replacement; instead, 3M VHB Foam (1879451-00-B) is applied over the abraded areas.

The procedure continues with correctly positioning the FFC in the rear passenger section and inspecting for existing anti-abrasion tape or foam. Depending on what is found, existing materials may be removed, the area cleaned, and new black anti-abrasion tape (1879451-99-A) or 3M VHB foam applied to protect the FFC where it contacts the vehicle. A clip attaching the FFC to the rearmost rib is released and re-secured.

In the front passenger section, any existing anti-abrasion tape is removed. The FFC is then routed through the LH channel of the cast ribbing, ensuring it lies flat and untwisted. A clip attaching the FFC to the front casting is removed and discarded. A new harness guide (2044121-00-A) is installed onto the front casting. The FFC is positioned into this guide using alignment marks, and electrical tape is used to secure the harness to the guide. Finally, the backbone harness and guide are secured to the front casting, and all previously removed interior components are reinstalled. The repair is completed using correction code S012417004 if only rerouting and guide installation are performed.

Required Tools or Parts

To perform the correction for the Tesla Cybertruck FFC misrouted condition, specific parts and tools are required:

Parts Required

• 2044121-00-A: FUB BACKBONE BRACKET, CT (Quantity: 1)

If Necessary Parts

• 1682221-00-G: HARNESS-MID VOLTAGE BACKBONE (Quantity: 1)
• 1879451-99-A: CLASS-G ANTI-ABRASION TAPE [50 x 150 MM] (Quantity: 1)
• 1879451-00-B: LV ABRASION STICKER,XM, HVB,CTSB (Quantity: 1, alternative to 1879451-99-A if not available)

Special Tools

• 1076972-00-A: Non-marring scraper set

Shop Supplies

• Electrical tape
• IPA wipes
• Paint Pen

Owner Action

If you own a 2024 Tesla Cybertruck, it is recommended to contact a Tesla Service Center to determine if your vehicle is affected by Service Bulletin SB-24-17-004. The service center will be able to check your vehicle's applicability and perform the necessary inspection and repair to address the Tesla Cybertruck FFC misrouted condition. This is a campaign bulletin, indicating Tesla is proactively addressing this condition.

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Source: NHTSA ID: 11008773