2024 Tesla Cybertruck Ancillary Harness Inspection TSB

Tesla has issued Service Bulletin SB-24-16-008, dated December 6, 2024, to address a potential issue with the High Voltage (HV) battery ancillary harness in certain 2024 Cybertruck vehicles. This bulletin outlines a procedure for inspecting and, if necessary, reworking or replacing the Tesla Cybertruck ancillary harness.

Symptoms

On affected 2024 Cybertrucks, the HV battery ancillary harness might be improperly routed. This improper routing can strain the harness branches and their connectors, specifically between the High Voltage Controller (HVC) and the Battery Management Boards (BMBs). While full communication failure is unlikely due to redundant connections, this strain could potentially prevent proper communication through one of the two harness branches.

The service bulletin indicates that technicians should inspect the vehicle for symptoms related to this condition when the ancillary cover is already removed for other service procedures.

Diagnosis / Trigger Conditions

This inspection is typically performed when the HV battery ancillary bay cover is already removed for other service. Technicians are instructed to visually inspect the two HV battery ancillary harness branches connected to the BMBs. They will look closely at the harness bundles, wire terminals, and connector housings for any signs of strain or damage.

If the harness branches appear strained or taut, further inspection is required to determine if there is actual damage. If any damage is observed, the harness will need replacement.

Repair Procedure Summary

The repair procedure involves either reworking or replacing the Tesla Cybertruck ancillary harness, depending on the inspection findings. All procedures must be performed by technicians trained in High Voltage Awareness and proper personal protective equipment (PPE) must be worn.

If the harness branches are in good condition but show signs of strain, a rework procedure (correction code S012416008) is performed. This involves:

1. Marking the HV battery ancillary harness 20 mm to the right side of the BMB harness clip using a paint pen.
2. Carefully cutting and removing the existing cable tie from the BMB harness clip, ensuring all pieces are removed to prevent debris.
3. Positioning a new cable tie through the BMB harness clip and around the ancillary harness, but not fully tightening it yet.
4. Pulling the ancillary harness to the left side of the ancillary bay until the paint pen mark aligns with the new cable tie.
5. Tightening the new cable tie sufficiently to hold the harness securely, but without overtightening to avoid damage.
6. Cutting the excess cable tie and tucking the head into the ancillary bay, again ensuring no debris is left.

If the harness branches are found to be damaged during the initial inspection, the harness must be replaced (correction code S022416008).

Required Tools or Parts

For this procedure, the following specific tools and parts may be required:

• Part Number: 1682237-00-H (ANCILLARY LOW VOLTAGE HARNESS) - if replacement is necessary.
• Ruler or measuring tape
• SKT, 3/8" DR, 10EP TORX PLUS EXTERNAL (for replacement)
• ThreeBond 1216E Silicone Type Liquid Gasket (for replacement)
• TOOL, CAULKING & ADHESIVE GUN, M18 (for replacement)
• KNIPEX 98 54 1,000V Insulated Cable Knife (for replacement)
• Cable ties
• Paint pen

Owner Action

Owners of 2024 Tesla Cybertruck vehicles should be aware of this service bulletin. While no specific owner action is typically required for service bulletins unless a symptom is observed, it is advisable to mention Service Bulletin SB-24-16-008 to your Tesla service center if your vehicle is undergoing other service that requires opening the HV battery ancillary bay, or if you experience any unusual electrical or communication issues that might be related to the HV battery system.

NHTSA ID: 11012220