2024 Tesla Cybertruck FFC Misrouted Cable TSB

Tesla has released Service Bulletin SB-24-17-004 to address an issue with the backbone harness Flat Flex Cable (FFC) in certain 2024 Cybertruck vehicles. This condition, where the FFC might be misrouted, is not safety-related but has the potential to cause damage to the cable over time.

Symptoms

While there are no direct warning lights or immediate operational symptoms, the primary concern is the potential for physical damage to the Flat Flex Cable (FFC). A misrouted FFC can experience abrasion or other forms of wear, which could eventually lead to electrical issues if the cable's internal wires become exposed.

Important Warnings

Owners and technicians should be aware of specific instructions to ensure the correct repair and prevent further damage:

• "CAUTION: Make sure to inspect the topside and underside of the FFC."
• "CAUTION: Do not wrap the cable in the 3M VHB foam. Only apply the foam to the flat side of the cable. Wrapping the cable may cause damage to the cable due to excessive heat."
• "CAUTION: Make sure the cable is flat against the casting and is not twisted."
• "NOTE: This bulletin is applicable to the vehicle, perform the correction without any need for inspection." This means if your vehicle is covered by SB-24-17-004, the repair should proceed without a preliminary diagnostic inspection to confirm the misrouting.
• "NOTE: Use PN: 1879451-99-A, if available. If PN: 1879451-99-A is not available, use PN: 1879451-00-B."
• "NOTE: Apply the sticker to the vehicle, not the FFC."
• "NOTE: Make sure the rib groove is aligned and engaged correctly. The lower engagement point will make an audible click when secured."

Diagnosis / Trigger Conditions

Diagnosis involves a thorough visual inspection of the Flat Flex Cable (FFC) in both the front and rear passenger sections of the vehicle. Technicians will look for signs of abrasion or damage, particularly exposed inner wires. If exposed wires are found, the Mid Voltage (MV) backbone harness will require replacement. If only abrasions are present on the outer cover, the FFC can be repaired with abrasion tape and foam. If no damage or abrasions are found, the FFC will be rerouted and a harness guide installed.

Repair Procedure Summary

The repair outlined in Service Bulletin SB-24-17-004 involves several steps to access, inspect, and correct the Flat Flex Cable (FFC) routing. The procedure begins with preparing the vehicle by opening doors and lowering windows, then removing various interior trim components, including the RH mid and lower A-pillar trims, footwell cover, and RH center floor rail. The RH front carpet and support foam, along with the rear carpet, are also removed to gain access.

Once the FFC is accessible, technicians will carefully inspect its front and rear passenger sections for any abrasions or damage. If severe damage, such as exposed inner wires, is found, the entire Mid Voltage backbone harness (PN 1682221-00-G) is replaced, and the repair is completed using Correction Code S022417004. For minor abras, 3M VHB Foam (PN 1879451-00-B) is applied to the affected areas, ensuring the cable is not fully wrapped to prevent heat buildup.

The FFC is then carefully positioned flat in the rear passenger section. Technicians will check for existing anti-abrasion tape and apply new black anti-abrasion tape (PN 1879451-99-A or 1879451-00-B) to the rearmost rib where the FFC may contact the vehicle. Any existing red 3M VHB Foam is removed, and the area is cleaned before new tape is applied to the vehicle, not the FFC itself. The FFC's clip to the rearmost rib is then 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 is not twisted. A clip attaching the FFC to the lower edge of the front casting is removed and discarded. A new harness guide (PN 2044121-00-A) is installed onto the front casting. The FFC is positioned on this guide, marked for alignment, and then secured to the guide with electrical tape. Finally, the backbone harness and guide are secured to the front casting, ensuring proper engagement.

The procedure concludes with the reinstallation of all removed interior components, including carpets, support foam, floor rail, footwell cover, and A-pillar trims. The vehicle's windows are raised, and doors are closed. The repair is finalized using Correction Code S012417004 if the FFC was rerouted and a guide installed, or S022417004 if the harness was replaced.

Required Tools or Parts

To perform the repair described in Service Bulletin SB-24-17-004, specific parts and tools are required:

• Harness Guide: FUB BACKBONE BRACKET, CT (PN 2044121-00-A)
• Replacement Harness (If Necessary): HARNESS-MID VOLTAGE BACKBONE (PN 1682221-00-G)
• Anti-Abrasion Tape/Sticker: CLASS-G ANTI-ABRASION TAPE [50 x 150 MM] (PN 1879451-99-A) or LV ABRASION STICKER,XM, HVB,CTSB (PN 1879451-00-B)
• Special Tools: Non-marring scraper set (PN 1076972-00-A)
• Shop Supplies: Electrical tape, IPA wipes, Paint Pen

Owner Action

If you own a 2024 Tesla Cybertruck, it is recommended to contact your local Tesla service center to determine if your vehicle is affected by Service Bulletin SB-24-17-004. While the condition of a potentially misrouted Flat Flex Cable (FFC) is not safety-related, addressing it proactively can prevent future cable damage. The repair involves inspecting, rerouting, or replacing the FFC and installing a harness guide. This service is performed under a campaign bulletin, meaning it addresses a known condition and provides recommended technical diagnosis and repair procedures for applicable vehicles. The Tesla Cybertruck FFC misrouted cable issue should be resolved by a certified technician.

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Source: NHTSA ID: 11008797