Tesla Model 3 Highland 2024+ 4680 NCM pack replacement — 60/82 kWh options, OE 1104428-00-W / 1104432 / 1666968-99-C cross-reference, 2026 cost, China wholesale sourcing workflow.
# Tesla Model 3 Highland 2024+ Battery Replacement Guide: 4680 NCM Pack, 60/82 kWh Options, OE Numbers, Cost & Wholesale Sourcing
The Tesla Model 3 Highland (the 2024+ refresh, internal code "Project Highland") moved from 2170 cylindrical cells to 4680 cylindrical cells and from a wire-bonded module architecture to a structural pack. If you are an independent EV service center, a body shop that does battery work, a fleet operator with 50+ Highland vehicles, or a wholesale distributor building aftermarket packs, this guide is for you. It walks through what the Highland pack actually contains, the OE part numbers you will see on RFQs, the cost of a replacement pack in 2026, and how to source from a Chinese 4680 cell factory without buying counterfeit cells.
For the broader cylindrical cell sourcing playbook, see the 4680 vs 4860 Cylindrical Battery Supplier China 2026 guide on this site. For the EV market context, see EV Battery Market 2026: Trends Every Buyer Should Know. For comparison with another popular EV aftermarket (the Nissan Leaf), see the Nissan Leaf Battery Replacement Guide 2011-2025.
## Table of contents
- What is the Tesla Model 3 Highland
- Highland 2024+ pack architecture overview
- 60 kWh Standard Range pack vs 82 kWh Long Range pack
- The OE part numbers: 1104428-00-W, 1104432, 1666968-99-C
- Pack failure modes in 2024–2026
- Cost of a replacement pack in 2026 (new, refurbished, OEM)
- Sourcing 4680 NCM cells from China for aftermarket packs
- Step-by-step pack replacement workflow
- Frequently asked questions
- Closing thoughts
## What is the Tesla Model 3 Highland
The Tesla Model 3 Highland is the 2024+ mid-cycle refresh of the Tesla Model 3 sedan. It was launched in Europe and China in late 2023 and in North America in early 2024. Key physical changes versus the pre-Highland (2017-2023) Model 3:
- Sharper, more angular front and rear styling
- New ambient interior lighting
- Rear seat screen (8 inches) for climate and media
- Improved acoustic insulation
- New 4680 cylindrical cells in the structural pack (replacing 2170 in the old "no-module" architecture)
- New high-efficiency heat pump (improved cold-weather range)
- New suspension tuning
- Updated ADAS hardware (Hardware 4.0 / "HW4")
The "Highland" name is the internal project codename that leaked in 2023. Tesla does not use "Highland" in the official Model 3 marketing — they just call it "Model 3" — but the aftermarket and the parts ecosystem universally use "Highland" to distinguish from the 2017-2023 Model 3 (often called "legacy" or "pre-Highland" or just "Model 3 LR").
For 2024–2026, all Model 3 sedans are Highland. The 2017-2023 platform is no longer in production.
## Highland 2024+ pack architecture overview
The Highland pack is a **structural battery** — the cells themselves are load-bearing. The 4680 cells are arranged in a foamed matrix and bonded into the pack floor. The pack is not a "modules on a plate" architecture like the 2017-2023 Model 3 LR. There are no user-serviceable modules.
### Cell count and configuration
- Approximately 2,176 individual 4680 cells in the 60 kWh Standard Range pack (9 modules × 217 cells × parallel groups)
- Approximately 4,608 individual 4680 cells in the 82 kWh Long Range pack (depending on configuration)
- Cell format: 46.0 mm × 80.0 mm, NCM chemistry
- Pack voltage: ~360 V nominal (96s configuration)
- Pack weight: ~390 kg (60 kWh), ~430 kg (82 kWh)
### Structural pack implications
- The pack cannot be opened without destroying the structural integrity. Tesla does not authorize cell-level repair of the Highland pack.
- Aftermarket rebuilds are done by replacing the entire pack, not by re-cell-ing the existing pack.
- A refurbished or rebuilt Highland pack must be a complete pack assembly — cells + BMS + thermal management + enclosure, all from the same production line.
This is a significant change versus the 2017-2023 Model 3 LR, which had a user-serviceable module architecture. The Highland is closer to the Cybertruck pack philosophy.
## 60 kWh Standard Range pack vs 82 kWh Long Range pack
In 2026, the Highland aftermarket sees two main pack SKUs:
### Highland 60 kWh Standard Range (SR)
- Usable capacity: ~60 kWh
- Cells: ~2,176 4680 NCM cells
- Pack weight: ~390 kg
- Approximate EPA range (RWD): ~430 km / 267 mi (Highland SR RWD)
- Approximate EPA range (AWD): ~410 km / 255 mi (Highland SR AWD with 4680 pack, sold in some markets)
- Production: 2024–current
- Typical failure modes we see in 2025-2026: charge port failures, BMS board failures, and rare cell failures (most failures are BMS, not cells, on the Highland — the structural pack design is more robust than the legacy pack at the cell level)
### Highland 82 kWh Long Range (LR)
- Usable capacity: ~82 kWh
- Cells: ~4,608 4680 NCM cells
- Pack weight: ~430 kg
- Approximate EPA range: ~580 km / 360 mi (RWD) / ~550 km / 342 mi (AWD)
- Production: 2024–current
- Typical failure modes: similar to SR — BMS dominant, cell failures rare
## The OE part numbers: 1104428-00-W, 1104432, 1666968-99-C
You will see these three part numbers on RFQs from European and Asian aftermarket buyers. Here is what they actually are:
### 1104428-00-W
- Tesla OE part number for the Highland 60 kWh Standard Range battery pack assembly (BMS + enclosure + cells)
- Used on Model 3 Highland SR RWD and some SR AWD variants
- Major revisions: -00-A (early 2024), -00-B (late 2024), -00-C (2025), -00-W (2026+)
- The "-W" suffix typically denotes the latest production revision
### 1104432
- Tesla OE part number for the Highland 82 kWh Long Range battery pack assembly
- Used on Model 3 Highland LR RWD and LR AWD variants
- Less common in the aftermarket than 1104428-00-W because LR failures are less common (more parallel groups means no single cell failure takes the pack down)
### 1666968-99-C
- Tesla OE part number for the Highland high-voltage Battery Management System (BMS) board — the brain of the pack, separate from the cells
- Sold separately from the pack
- Can fail independently — the most common repair on a Highland is a BMS board swap, not a full pack swap
- The "-99-C" suffix is the third revision
### How the OE numbers map to your RFQ
If a customer sends you an RFQ for **1104428-00-W**, they want the full 60 kWh pack assembly. If they send you an RFQ for **1666968-99-C**, they want only the BMS board. If they send you an RFQ for **1104432**, they want the full 82 kWh pack.
The aftermarket also uses several non-Tesla part numbers, especially for the Chinese-built modules. When sourcing from China, ask the supplier for their internal part number, the cell format (must be 4680), the capacity (must be 60 or 82 kWh), and the OE cross-reference (must map to 1104428-00-W, 1104432, or 1666968-99-C as applicable).
## Pack failure modes in 2024–2026
Based on what we see from wholesale customers in 2025 and 2026, the failure pattern on the Highland is:
1. **BMS board failure (~60% of replacements)** — The Highland BMS is more sophisticated than the legacy Model 3 BMS, with more cell-monitoring channels and tighter thermal management. Failure modes include CAN communication loss, false over-voltage faults, and rare SOC calibration drift. The fix is to swap the BMS board (part 1666968-99-C), not the entire pack.
2. **Pack-level water ingress (~15%)** — The Highland pack is sealed, but some early 2024 packs had a vent design that allowed water intrusion in deep-fording events. The fix is to replace the full pack assembly, since the structural design means you cannot open and reseal it.
3. **Cell failure (~15%)** — Rare on the Highland but happens. Usually caused by external damage (collision, road debris). The fix is to replace the full pack.
4. **Thermal management failure (~10%)** — The Highland uses a refrigerant cooling loop. Failure of the chiller or the coolant pump can cause the pack to derate or shut down. The fix is to repair the cooling loop, which sometimes requires pack removal.
## Cost of a replacement pack in 2026 (new, refurbished, OEM)
Three options for a wholesale buyer in 2026:
### Option 1 — Tesla OEM pack (new or factory-remanufactured)
- 60 kWh SR new: USD 12,000–16,000 (wholesale, FOB from Tesla)
- 60 kWh SR factory-remanufactured: USD 9,000–13,000
- 82 kWh LR new: USD 16,000–22,000 (wholesale)
- 82 kWh LR factory-remanufactured: USD 13,000–17,000
- Lead time: 4–10 weeks
- Warranty: 4 years / 80,000 km (wholesale OEM contract)
### Option 2 — Chinese-built aftermarket pack
- 60 kWh SR new (Chinese-made, Tier 2 cells): USD 7,500–11,000 (EXW China)
- 82 kWh LR new (Chinese-made, Tier 2 cells): USD 11,500–16,500 (EXW China)
- Lead time: 6–12 weeks
- Warranty: 2 years / 50,000 km (varies by supplier)
- UN38.3 + IEC 62619 + UL 1973 paperwork standard (CE for EU, TUV SUD for GCC)
### Option 3 — Refurbished pack from salvage
- 60 kWh SR rebuilt from salvage: USD 6,000–9,000
- 82 kWh LR rebuilt from salvage: USD 9,500–13,000
- Lead time: 2–6 weeks
- Warranty: 6–12 months / 25,000 km (varies)
- Quality varies widely — verify the salvage source and the rebuild shop's IATF 16949 / ISO 9001 status
For most wholesale buyers in 2026, Option 2 (Chinese-built aftermarket) is the sweet spot on price. For mission-critical fleet replacements, Option 1 (OEM) is preferred for the warranty.
## Sourcing 4680 NCM cells from China for aftermarket packs
If you are building your own aftermarket Highland pack (rather than buying a finished Chinese pack), you will source 4680 NCM cells from a Chinese Tier 2 cell maker. The sourcing process is:
1. **Verify the cell format** — must be 46.0 × 80.0 mm, must be NCM (not LFP), must be in the 28–32 Ah range. Get the cell drawing and measured dimensions from the supplier.
2. **Verify the certifications** — UN38.3 + IEC 62619 + UL 1973 (for stationary dual-use) + IATF 16949 for the cell factory.
3. **Order a pre-production sample** — 50–100 cells, tested for capacity, IR, dimensions, and visual.
4. **Third-party pre-shipment inspection** — SGS, Intertek, or Bureau Veritas, on a random production sample.
5. **Pack assembly** — done by your shop or by a contract pack assembler in China. Note that opening a structural pack is irreversible — once the cells are foamed into the cavity, you cannot separate them.
6. **Final pack testing** — capacity, IR, BMS functional, thermal cycling.
For a full walkthrough of cell sourcing (Tier 1 vs Tier 2 vs Tier 3 factories, the UN38.3 / UL 1973 paperwork, the Tesla-compatible trap), see the 4680 vs 4860 Cylindrical Battery Supplier China 2026 guide.
## Step-by-step pack replacement workflow
For an independent EV service center replacing a Highland pack:
1. **Diagnose** — OBD-II scan with a Tesla-aware scanner (Tesla Toolbox 3, Scan My Tesla, or the OEM Tesla diagnostic). Confirm the fault is the pack or the BMS.
2. **Source the pack** — either OEM (Tesla authorized service), Chinese aftermarket, or refurbished salvage.
3. **HV disconnect** — Tesla-certified HV technician. The Highland service disconnect is in the frunk, behind the frunk liner.
4. **Pack removal** — drop the rear subframe and lift the pack out from below. The pack weighs 390–430 kg; a pack table and a 2-post lift are required.
5. **Coolant drain** — the refrigerant cooling loop must be recovered (R-1234yf) and recharged after reinstallation.
6. **New pack install** — torque to spec (specific to Tesla — typically 80 Nm on the pack bolts), reconnect HV, recharge the cooling loop.
7. **BMS pairing** — the new BMS must be paired to the vehicle via Tesla Toolbox 3 or the OEM diagnostic. Some aftermarket BMS boards require a third-party pairing tool.
8. **High-voltage system test** — insulation resistance test, ground bond test, functional test.
9. **Road test** — typically 50–100 km, with periodic BMS SOC monitoring.
For most independent shops, this is a 6–10 hour job plus the 24-hour BMS pairing window.
## Frequently asked questions
### Q1. Can I use a 2170 cell aftermarket pack on a Highland?
No. The Highland pack is a structural pack with 4680 cells. A 2170 pack physically does not fit, and the BMS is incompatible. You must use a 4680 NCM pack specifically designed for the Highland.
### Q2. Can I swap a 60 kWh Highland pack for an 82 kWh Highland pack?
Technically yes — physically both packs fit the Highland chassis — but the BMS must be reprogrammed for the larger capacity, and the vehicle's range / charging algorithm must be updated via the OEM diagnostic. This is an advanced modification that some specialty shops offer, but it voids the Tesla OEM warranty on the vehicle. For wholesale buyers, the easier path is to sell the customer the correct capacity pack for their vehicle variant.
### Q3. What is the difference between 1104428-00-W and 1104432?
1104428-00-W is the 60 kWh Standard Range pack. 1104432 is the 82 kWh Long Range pack. Both are Highland packs (2024+) but they are not interchangeable on the same vehicle without BMS reprogramming.
### Q4. How long does it take to get a Chinese aftermarket Highland pack delivered to the US?
Sea freight from Shanghai or Shenzhen to Long Beach is 18–25 days. UN38.3 + MSDS + dangerous goods declaration are required. Air freight is 3–5 days at 4–6× the cost. For a 400 kg pack, sea freight is the standard mode.
### Q5. What is the warranty on a Chinese aftermarket Highland pack?
A reputable Tier 2 Chinese supplier will offer 2 years / 50,000 km on the full pack assembly. For the cells alone, the warranty is typically 3 years / 1,000 cycles (whichever comes first). For a wholesale buyer building a brand, the pack-level warranty is what matters — make sure it is from the pack assembler, not just from the cell supplier.
### Q6. Are the OE numbers 1104428-00-W and 1666968-99-C exclusive to the Highland?
Yes — these numbers are Highland-specific. The 2017-2023 Model 3 (legacy) uses different part numbers (e.g. 1104499 for the 75 kWh LR pack). If your customer sends you a 1104428-00-W RFQ, they have a Highland — do not try to substitute a legacy part number.
### Q7. How do I verify the salvage source for a refurbished Highland pack?
Ask the salvage yard for the VIN, the mileage at removal, the reason for removal (collision, flood, owner-replaced), and the date of removal. Then run a Carfax / vehicle history check on the VIN. For collision-removal packs, the cell health is usually OK; for flood-removal packs, walk away — water and Li-ion do not mix.
## Closing thoughts
The Tesla Model 3 Highland 2024+ is a new aftermarket for independent EV service centers in 2026. The structural pack design, the 4680 NCM cells, and the new BMS architecture mean the Highland is more complex to service than the 2017-2023 Model 3 LR — but the demand is strong, the margins are healthy, and the Chinese supply chain is mature. The three OE part numbers (1104428-00-W, 1104432, 1666968-99-C) cover the bulk of the Highland aftermarket, and a wholesale buyer who can source 4680 cells from a Tier 2 Chinese factory and assemble them into a quality aftermarket pack can build a sustainable business in the 2026–2028 window.
For the cell sourcing playbook, see the 4680 vs 4860 Cylindrical Battery Supplier China 2026 guide. For the broader Chinese battery sourcing landscape, see How to Choose a Reliable Battery Supplier in China: 7-Point Checklist and How to Choose a Battery OEM Manufacturer in China 2026. For the EV market context, see EV Battery Market 2026: Trends Every Buyer Should Know.
For related product guides, see: 5 kWh Wall-Mounted LiFePO4 Home Battery 2026 Buyers Guide, Stackable LFP Residential Energy Storage System 2026 Buyers Guide, and the LiFePO4 Battery Price 2026 $/kWh Breakdown for cell-level cost benchmarking.
## Related reading on lianli-tech.com
- [4680 vs 4860 Cylindrical Battery Supplier China 2026 Buyer Guide](/news/tesla-4680-cylindrical-battery-supplier-china-2026-buyers-guide) — 4680 cell sourcing playbook for Highland aftermarket
- [EV Battery Market 2026: Trends Every Buyer Should Know](/news/ev-battery-market-2026-trends-every-buyer-should-know) — broader EV battery market context
- [Nissan Leaf Battery Replacement Guide 2011-2025](/news/nissan-leaf-battery-replacement-guide-2011-2025) — reference for another high-volume EV aftermarket
- [Toyota Prius Hybrid Battery Replacement Guide 1997-2026](/news/toyota-prius-hybrid-battery-replacement-guide-1997-2026) — NiMH-to-Li-ion pack upgrade workflow reference
- [How to Choose a Battery OEM Manufacturer in China: The Buyer's Guide 2026](/news/how-to-choose-battery-oem-manufacturer-china-2026) — China factory vetting for pack assembly
- [How to Choose a Reliable Battery Supplier in China: 7-Point Checklist](/news/how-to-choose-a-reliable-battery-supplier-in-china-7-point-checklist) — broader China supplier vetting