2024 Tesla Cybertruck Flat Flex Cable Misrouting SB-24-17-004

Tesla has released Service Bulletin SB-24-17-004 for certain 2024 Cybertruck vehicles. This campaign bulletin addresses a non-safety-related condition concerning the backbone harness Flat Flex Cable (FFC).

Symptoms

On certain 2024 Tesla Cybertruck vehicles, the backbone harness Flat Flex Cable (FFC) might be misrouted. This misrouting can potentially cause damage to the cable over time. While no immediate driver-facing symptoms are noted, the underlying issue is the risk of cable damage.

Diagnosis / Trigger Conditions

Technicians will inspect the front and rear passenger sections of the Flat Flex Cable (FFC) for any abrasions or damage. This inspection includes both the topside and underside of the FFC. If the Tesla Cybertruck Flat Flex Cable shows signs of exposed inner wires, it indicates damage requiring replacement. If only abrasions to the outer cover are found, the FFC does not need to be replaced, but further action is required.

Repair Procedure Summary

The repair for the Tesla Cybertruck Flat Flex Cable involves several steps to ensure proper routing and protection:

1. Initial Access: All doors and windows are opened, and various interior trims and carpets (RH mid A-pillar, RH lower A-pillar, footwell cover, RH center floor rail, RH front carpet, rear carpet) are removed to access the FFC.
2. FFC Inspection: The Flat Flex Cable is thoroughly inspected for abrasions or damage. If severe damage (exposed inner wires) is found, the Mid Voltage (MV) backbone harness is replaced, and the procedure is discontinued, using Correction Code S022417004.
3. Abrasion Repair: If only abrasions are present, 3M VHB Foam (PN: 1879451-00-B) is applied to the FFC over the abraded areas. The cable must be positioned flat at the rear passenger section.
4. Anti-Abrasion Tape/Foam Application: The rearmost rib under the FFC is inspected for existing red 3M VHB foam or black anti-abrasion tape (PN: 1879451-99-A). Depending on availability and current installation, existing foam may be removed, the area cleaned, and new black anti-abrasion tape or 3M VHB Foam applied to cover potential contact points.
5. FFC Rerouting: Any anti-abrasion tape attaching the FFC to the front casting is removed. The FFC is then routed through the LH channel of the cast ribbing, ensuring it lies flat and is not twisted.
6. Harness Guide Installation: A new harness guide (PN: 2044121-00-A) is installed onto the front casting. The FFC is positioned flat on the guide and marked for alignment.
7. Securing the FFC: The FFC is secured into the harness guide using electrical tape at marked positions.
8. Final Assembly: The backbone harness and harness guide are secured to the front casting, ensuring proper engagement. All previously removed interior components, including carpets, trims, and covers, are reinstalled. The correction is completed using Correction Code S012417004.

Required Tools or Parts

To perform this correction on the Tesla Cybertruck Flat Flex Cable, specific parts and tools are required:

Parts Required:

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

If Necessary:

• 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)

Special Tools:

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

Shop Supplies:

• Electrical tape
• IPA wipes
• Paint Pen

Important Warnings

Owners and technicians should be aware of the following critical instructions:

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