2024 Tesla Model 3/Y HV Battery Replacement TSB

Tesla has issued Service Bulletin SB-25-16-001 to address a potential issue with the high voltage (HV) battery in certain 2024 Model 3 and Model Y vehicles. This campaign bulletin focuses on a non-safety-related condition that could impact vehicle performance.

The bulletin specifies that affected vehicles may have HV batteries containing cell modules that do not meet Tesla's stringent internal quality standards. This manufacturing discrepancy can lead to a noticeable reduction in the vehicle's overall driving range.

Important Warning for Owners

Tesla has stated that if this bulletin, SB-25-16-001, is applicable to your vehicle, the correction procedure should be performed without any prior inspection. This means technicians are directed to proceed directly with the repair once applicability is confirmed.

Repair Procedure Summary

The primary correction for this issue is the replacement of the entire HV battery assembly. This procedure is detailed in Service Manual procedure 16010202, specifically for 2024+ Model 3 and Model Y vehicles. The estimated labor time for this repair is approximately 4.56 hours for the Model 3 and 4.98 hours for the Model Y.

This repair ensures that your Tesla Model 3 HV battery or Model Y HV battery meets the manufacturer's quality standards, restoring the expected driving range.

Required Parts

Technicians will require specific parts for the HV battery replacement. These include:

• 1093060-00-A: NUT&WSHR,M8,STL[9],DOUBLE SEMS (Quantity: 2)
• 1461657-00-A: BOLT,HF,M14-2.0x120,[109],ZNFL, CMAT (Quantity: 2)
• 1467057-00-F: SEAL, PERIMETER,PENTHOUSE,MDL3 (Quantity: 1)

One of the following HV battery assemblies will be used, depending on the vehicle's configuration:

• 1234422-00-A: ASY, HVBAT,E3,AWD,1PH,M3Y (Quantity: 1)
• 1234424-00-A: ASY, HVBAT,E3,RWD,1PH,M3Y (Quantity: 1)

For Model 3 vehicles, additional parts are required:

• 1111033-00-E: M3 2R BOLSTER CLIP (Quantity: 1)
• 1458818-00-B: BOLT,PF,M10-1.5x36,[109],G0310[B],SMAT (Quantity: 8)

Special Tools

Several specialized tools are necessary to safely and correctly perform the HV battery replacement:

• 1020566-00-F: ASY, Battery Table, Manual Lift
• 1020566-99-A: Top Plate, Battery Table, Manual Lift
• 1129166-00-A: Hoist, H-Frame
• 1134523-00-A: Kit, Alignment Rods, Battery
• 1140311-00-A: Lever Lock, HV Connector
• 1053600-00-B: Drive Unit Pressure Test Fixture
• 1130942-00-B: Adapter, Coolant Reservoir Pressure Test
• 1132185-00-B: Kit, Coolant Leak Test Adapters
• 1133843-00-A: Kit, Coolant Drain & Fill Adapters
• 1135762-00-A: Kit, Svc Plug, Cooling Hose
• GSN-TL-000564: Kit, Battery Coolant Drain and Fill
• 1026636-00-A: Pack Enclosure Leak Tester, HV Battery
• 1140501-00-A: Pack Kit, Enclosure, Leak Test, HV Battery, Complete
• 1144879-00-A: Kit, Encl Leak Test Adapters, HV Battery
• 1108272-00-B: Cap, Logic Conn, Inv, 3DU
• 1076921-00-B: Insulation Multimeter, Fluke 1507
• 1050448-00-A: Refiller, Cooling System
• 1073363-00-A: Gantry, Adjustable, Aluminum
• 1453419-00-A: Adapter, Lift Pad, Model 3
• 1133787-00-A: Key, Seat Belt Release, Model 3
• 1130480-00-A: Test Probes, Slim, Fluke TP38

Shop Supplies

In addition to the special tools, technicians will need standard shop supplies such as shop towels, HV insulating gloves, leather outer gloves, Isopropyl Alcohol (IPA) wipes, and Penetrox A13 compound (1019168-00-A).

Owner Action

If you own a 2024 Tesla Model 3 or Model Y and suspect your vehicle's driving range has been reduced, or if you receive notification regarding Service Bulletin SB-25-16-001, contact your authorized Tesla service center. They will be able to confirm if your vehicle is affected and schedule the necessary HV battery replacement. This repair is a campaign bulletin, indicating it addresses a condition that Tesla is proactively correcting.

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Source: NHTSA ID: 11016320