Rear Drive Inverter - Drive Inverter (Remove and Replace)
Correction code 4020092022 FRT 3.60 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-08-21: Rearrange bootloader steps to the correct order.
- 2024-07-09: Added note and tip for accessing the RH motor mount bolt.
- 2024-05-01: Added a 'Note" to the leak test adapter to make sure the surfaces are clean and free to debris, and the adapter is fully seated to prevent false test failure.
- 2024-03-14: Updated torque specification for the lower tub crossmember bolts.
Remove
- Open the LH front door and lower the LH front window.
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
- Unlock the vehicle Gateway. See Gateway (Unlock).
-
On the vehicle touchscreen, navigate to Run, and allow the routine to
complete.
, and then touch NoteTouch Close once completed.
- Open the tonneau cover.
- Open the tailgate.
- Remove the bed cargo tub struts from the cargo lid, but do not remove the struts from the vehicle. See Tonneau - Bed Cargo Tub Strut (Remove and Install).
- Remove the bed cargo tub lid. See Bed Cargo Tub - Bed Cargo Tub Lid (Remove and Replace).
- Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
- Remove the LH and RH rear bed closeouts. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
- Remove the LH and RH tonneau water management seals. See Tailgate Seals - Tonneau Water Management Seal, LH, Center (Remove and Install).
-
Remove the LH and RH upper tie down hooks.
Notex1 bolt each side
- Remove the LH and RH upper bed side wall assemblies. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install).
- Remove the LH and RH bed side walls. See Bed Side Wall - Bed Side Wall - LH (Remove and Install).
- Remove the bed cargo smugglers bay. See Bed Cargo Tub - Bed Cargo Smugglers Bay (Remove and Install).
- Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Disconnect MV power. See Disconnect MV Power.
- Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
- Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
- Remove the leather over gloves and HV insulating gloves.
-
Remove the bolts (x2) that attach the
lower tub crossmember.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
-
Put the coolant drain below the rear inverter.
-
Remove the coolant hose from the rear inverter lower fitting.
Notex1 clip, x1 hose clipNotePlug both ends using the plugs from the Coolant Hose Plug Kit (1135762-00-A).NoteUse a long flathead screwdriver to release the clip on the hose, and then release the hose.
-
Release the clip that attaches the Rear Drive Unit (RDU) LV harness clip.
-
Release the clips (x2) that attach the lower portion of the rear inverter acoustic cover.
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Remove the bolts (x4) that attach the RDU HV harness bracket.
Tip: Use of the following tool(s) is recommended:
- Torx T30 socket
- Lower the vehicle until the tires are touching the ground.
-
Put the coolant catcher below the RDU.
-
Release the clips (x5) that attach the acoustic cover surrounding the RH motor mount.
-
Remove the coolant hose from the rear inverter upper fitting.
Notex1 spring clipNotePlug both ends after disconnecting the hose with plugs from the Coolant Hose Plug Kit (1135762-00-A).
-
Release the clip that attaches the rear inverter coolant hose to the gearbox housing.
NoteRotate the hose away from the inverter.
- Remove the coolant catcher from below the vehicle.
-
Disconnect the RDU HV cable from the RDU.
NoteDisengage the locking tab, and then release the connector body and move it aside.
-
Disconnect the RDU logic electrical connector.
NoteRelease the locking tab.CAUTIONDo not get coolant ingress into this electrical connector. Move aside as needed.
-
Release the RDU LV harness clip.
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Remove the bolt that attaches the ground strap the RDU.Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
-
Remove the label to access the phase out cover bolts.
NoteLabel is a one time use only. Discard the label after removal.
-
Remove the bolts (x2) that attach the phase out cover.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
NoteTorque: 5 Nm + 20 degrees -
Remove the phase out cover assembly.
NoteUse a plastic trim tool to aid in removal. If the phase out cover or O-rings are damaged, then replace it with a new part.
-
Remove the bolts (x3) that attach the 3 phase busbars to the drive inverter.
Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket (magnetic)
NoteTorque: 5 Nm + 43 degrees +/- 7 -
Release the clips (x5) that attach the acoustic cover surrounding the RH motor mount.
-
Position a floor jack to support the RDU.
-
Break the RH motor mount bolt loose.NoteVehicles may be equipped with a 16 mm bolt or a Torx E18 bolt.Tip: Insert the breaker bar from the RH side wheel well to access the bolt.Tip: Use of the following tool(s) is recommended:
- 16 mm socket or External Torx E18
- 2 in extension
- Breaker bar
-
Remove the bolts (x3) that attach the RH motor mount assembly.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP14
NoteTorque: 35 Nm + 55 degrees -
Remove the bolt that attaches the RH motor mount.
Tip: Use of the following tool(s) is recommended:
- External Torx E18
-
Remove the RH rear motor mount assembly from the rear subframe.
NoteAcoustic cover sits between the RH rear motor mount and the rear subframe.
-
Put on the ESD wrist strap and secure it to the inverter housing.
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Remove the bolts (x9) that attach the drive inverter to the RDU gearbox assembly.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
NoteTorque 6 Nm + 20 degreesNoteBolts can be reused. -
Remove the drive inverter from the RDU, and then drain the coolant from the inverter.
NoteGasket is a one time use only.CAUTIONAvoid damage to the printed circuit board.
-
Put the drive inverter on the ESD mat.
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Remove the ESD wrist strap from the old inverter.
Install
-
Prepare the new drive inverter.
NoteSave the packaging to MRB the old drive inverter.NoteRemove any red protective covers.
-
Secure the ESD strap on the new drive
inverter housing.
-
Clean the HV cable lugs with an
Isopropyl Alcohol (IPA) wipe to ensure the contact surfaces are free of debris.
NoteAllow 1 minute dry time.
-
Position the drive inverter to the
RDU, and then hand tighten the bolt.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
NoteHand tight first. Bolt tightening will be performed later in this procedure.Notex2 guide pinsNoteManeuver the drive inverter into position.NoteDo not damage the circuit board when maneuvering near the rear subframe.NoteThread in bolt to hold the drive inverter in place. -
Thread in and flush the bolts (x9)
that attach the drive inverter to the rear gearbox assembly.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
NoteBolts can be reused.NoteHand tighten first. Tighten sequence in next step. -
Tighten the drive inverter bolts (x9)
using the tightening sequence shown.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
NoteTorque: 6 Nm + 20 degrees -
Install the bolts (x3) that attach the
drive inverter to the 3 phase lugs.
Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket (magnetic)
NoteTorque: 5 Nm + 43 degrees +/- 7NoteIf installing new bots, torque to 12.5 Nm, reverse 180 degrees, and then torque to 5 Nm + 43 degrees +/- 7.NoteVerify all bolts are accounted for.NoteUse a magnet, as needed. -
Install the bolts (x2) that attach the
RDU phase out cover.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
NoteTorque: 5 Nm + 20 degrees -
Install a new phase out cover warning
label.
-
Remove the ESD wrist strap from the
drive inverter.
-
Take the old drive inverter and
prepare for MRB. Label properly for return or disposal.
NoteUse ESD wrist strap.NoteLabel the drive inverter for MRB and return to packaging.NoteSecure any protective red caps.NoteReturn or dispose of packaging through proper channels.
-
Install the leak test adapter plug
(1450875-00-A) to the electrical connector at the drive inverter.
NoteMake sure the surfaces are clean, free debris, and the adapter is fully seated otherwise a false test failure may occur.
-
Install the leak test adapter to the
RDU HV electrical connector.
NoteMake sure the surfaces are clean, free debris, and the adapter is fully seated otherwise a false test failure may occur.
-
Connect a regulator to adapter
(1026636-00-A) at the HV electrical connector.
-
Close both valves on the regulator
test tool.
-
Connect the regulator to air
supply.
-
Turn on the regulator, and then open
the valve closest to the regulator.
-
Set regulator to 1 psi.
-
Open the 2nd valve to inject air into
the RDU.
NoteClose the valve when pressure reaches 1 psi and stable.
- Wait 45 seconds for the pressure to settle.
- Record the start pressure valve.
- Wait 60 seconds for the test.
-
Record the end pressure valve.
- If the pressure did not drop more than 0.04 psi, continue to next step.
- If the pressure dropped more than 0.04 psi, then inspect for leaks.
-
Disconnect the air supply from the
regulator tool.
-
Disconnect the regulator from the leak
test adapter at the HV electrical connector.
-
Remove the leak test adapter from the
HV electrical connector.
-
Remove the leak test adapter plug from
the electrical connector at the drive inverter.
-
Position the RH side motor mount with
the acoustic cover into the rear subframe.
NoteManeuver between the RDU and the rear subframe.
-
Hand tighten the bolts (x4) that
attach the RH rear motor mount to the drive inverter and the rear subframe.
Tip: Use of the following tool(s) is recommended:
- External Torx E14
- External Torx E18
NoteTightening of the bolts at the next steps. -
Tighten the bolts (x4) that attach the
RH motor mount to the RDU.
Tip: Use of the following tool(s) is recommended:
- External Torx E14
NoteTorque: 35 Nm + 55 degreesNoteFollow the torque sequence shown. -
Tighten the RH rear motor mount bolt
to the rear subframe.NoteVehicles may be equipped with a 16 mm bolt or a Torx E18 bolt.Tip: Insert the torque wrench from the RH side wheel well to access the bolt.Tip: Use of the following tool(s) is recommended:
- 16 mm socket or External Torx E18
- 2 in extension
-
Remove the jack stand from supporting
the RDU.
-
Secure the RH side acoustic
cover.
Notex5 clipsNoteSecure the above clips and remaining from below.
-
Install the bolt that attaches the
ground strap to the RDU.Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
-
Secure the RDU electrical
harness.
Notex1 clip
-
Connect the HV electrical
connector.
NoteEngage the locking tab.
-
Position the coolant catcher below the
RDU.
-
Secure the rear inverter coolant hose
to the gearbox housing.
Notex1 hose clip
-
Install the coolant hose onto the rear
inverter upper fitting.
Notex1 spring clipNoteRemove plugs from both ends.NotePerform a push-pull test.
- Fully raise the vehicle.
-
Secure the lower acoustic cover clips
(x2).
-
Secure the RDU electrical harness
clip.
-
Connect the RDU logic electrical
connector.
NoteVerify that the lever is fully engaged.
-
Put the coolant drain below the drive
inverter.
-
Install the coolant hose onto the
drive inverter lower fitting.
Notex1 spring clipNoteRemove the plugs from both ends.NotePerform a push-pull-push test.
- Remove the coolant drain container from underneath the vehicle.
-
Install the bolts (x4) that attach the
RDU HV harness bracket.
Tip: Use of the following tool(s) is recommended:
- Torx T30 socket
-
Secure the RDU header connector to the
ancillary.
Notex1 electrical connectorNoteVerify the lever is in the upright and open position. Carefully seat electrical connector and allow the lever to engage. Fully secure the lever and verify the red tab is locked.CAUTIONDo not damage any pins.
-
Install the bolts (x2) that attach the
lower tub crossmember.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
- Install the mid aero shield. See Undertray - Mid Aeroshield (Remove and Install).
- Install the LH and RH wheels. See Wheel Assembly (Remove and Install).
- Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
- Reconnect MV power. See Disconnect MV Power.
-
On the vehicle touchscreen, touch
Stop Thermal Fluid
Fill/Drain, touch Run, and allow the routine
to complete.
NoteTouch Close once completed.
-
Touch Restore Application Data,
touch Run, and
allow the routine to complete.
NoteTouch Close once completed.
-
Touch Restore Bootloader Data after Perform
CAN Redeploy, touch Run, and allow the routine
to complete.
NoteTouch Close once completed.
- Touch Coolant Air Purge, touch Run, and allow the routine to complete.
-
Touch Thermal System Performance
Test, touch Run, and allow the routine to complete.
NoteTouch Close once completed.
-
Put stanchions around vehicle and set
up a safety perimeter before performing the resolver error learn.
NoteUse safety stanchions to section off the vehicle before driving the vehicle on the lift.
- Partially raise the vehicle.
-
Touch Resolver Error Learn, and
then touch Run.
Allow the routine to complete.
WarningRead the instructions thoroughly. Follow the appropriate safety precautions. Vehicle needs to be driven on a lift. Verify all wheels are clear of contacting ground.NoteVehicle software must be 2022.16.2 or later for routine to operate.
- Remove the safety stanchions from around vehicle after the resolver learn is completed.
- Install the bed cargo smugglers bay. See Bed Cargo Tub - Bed Cargo Smugglers Bay (Remove and Install).
- Install the LH and RH bed side walls. See Bed Side Wall - Bed Side Wall - LH (Remove and Install).
- Install the LH and RH rear bed closeouts. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
- Install the LH and RH upper bed side wall assemblies. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install)
- Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
- Install the bed cargo tub lid. See Bed Cargo Tub - Bed Cargo Tub Lid (Remove and Replace).
- Install the bed cargo tub struts. See Tonneau - Bed Cargo Tub Strut (Remove and Install).
- Close the tailgate.
- Close the tonneau cover.
- Raise the LH front window and close the LH front door.
-
Perform a test drive.
NoteDrive a minimum speed of 25 mph. Drive in a straight line and check for excessive pull. Verify the steering wheel is centered when vehicle is driving straight. Determine whether a wheel alignment is recommended.