22/05/2024 14:24:54

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.

2024-05-01: 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.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

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 on a 2 post lift. See Raise Vehicle - 2 Post Lift.
Unlock the vehicle gateway. See Gateway (Unlock).
On the vehicle touchscreen, touch Service Mode Plus > High Voltage.
Touch Procedures.
Touch Drive-Inverter-Replacement > Rear Drive Inverter Replacement.
Touch Store Boot + App Data and Start Fluid Fill/Drain, and then click Run. Allow the routine to complete.

Note
Touch 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 bolts (x4) that attach the bed cargo tub lid.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
Recommend assistance.
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 rail seals.

Note
x2 clips
Remove the LH and RH upper tie down hooks.

Note
x1 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).
Open the powered frunk.
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.
36 Nm (26.5 lbs-ft)
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.

Note
x1 clip, x1 hose clip

Note
Plug both ends using the plugs from the Coolant Hose Plug Kit (1135762-00-A).

Note
Use 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.
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.

Note
x1 spring clip

Note
Plug 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.

Note
Rotate the hose away from the inverter.
Remove the coolant catcher from below the vehicle.
Disconnect the RDU HV cable from the RDU.

Note
Disengage the locking tab, and then release the connector body and move it aside.
Disconnect the RDU logic electrical connector.

Note
Release the locking tab.

CAUTION
Do not get coolant ingress into this electrical connector. Move aside as needed.
Release the RDU LV harness clip.
Remove the bolt that attaches the ground strap the RDU.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
Remove the label to access the phase out cover bolts.

Note
Label 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
Note
Torque: 5 Nm + 20 degrees
Remove the phase out cover assembly.

Note
Use 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)
Note
Torque: 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.
85 Nm (62.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E18
Remove the bolts (x3) that attach the RH motor mount assembly.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP14
Note
Torque: 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.

Note
Acoustic 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.
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
Note
Torque 6 Nm + 20 degrees

Note
Bolts can be reused.
Remove the drive inverter from the RDU, and then drain the coolant from the inverter.

Note
Gasket is a one time use only.

CAUTION
Avoid damage to the printed circuit board.
Put the drive inverter on the ESD mat.
Remove the ESD wrist strap from the old inverter.

Install

Prepare the new drive inverter.

Note
Save the packaging to MRB the old drive inverter.

Note
Remove 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.

Note
Allow 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
Note
Hand tight first. Bolt tightening will be performed later in this procedure.

Note
x2 guide pins

Note
Maneuver the drive inverter into position.

Note
Do not damage the circuit board when maneuvering near the rear subframe.

Note
Thread 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
Note
Bolts can be reused.

Note
Hand 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
Note
Torque: 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)
Note
Torque: 5 Nm + 43 degrees +/- 7

Note
If installing new bots, torque to 12.5 Nm, reverse 180 degrees, and then torque to 5 Nm + 43 degrees +/- 7.

Note
Verify all bolts are accounted for.

Note
Use 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
Note
Torque: 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.

Note
Use ESD wrist strap.

Note
Label the drive inverter for MRB and return to packaging.

Note
Secure any protective red caps.

Note
Return or dispose of packaging through proper channels.
Install the leak test adapter plug (1450875-00-A) to the electrical connector at the drive inverter.

Note
Make 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.

Note
Make 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.

Note
Close 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.

Note
Maneuver 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
Note
Tightening 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
Note
Torque: 35 Nm + 55 degrees

Note
Follow the torque sequence shown.
Tighten the RH rear motor mount bolt to the rear subframe.
85 Nm (62.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E18
Remove the jack stand from supporting the RDU.
Secure the RH side acoustic cover.

Note
x5 clips

Note
Secure the above clips and remaining from below.
Install the bolt that attaches the ground strap to the RDU.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
Secure the RDU electrical harness.

Note
x1 clip
Connect the HV electrical connector.

Note
Engage the locking tab.
Position the coolant catcher below the RDU.
Secure the rear inverter coolant hose to the gearbox housing.

Note
x1 hose clip
Install the coolant hose onto the rear inverter upper fitting.

Note
x1 spring clip

Note
Remove plugs from both ends.

Note
Perform 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.

Note
Verify that the lever is fully engaged.
Put the coolant drain below the drive inverter.
Install the coolant hose onto the drive inverter lower fitting.

Note
x1 spring clip

Note
Remove the plugs from both ends.

Note
Perform 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.

Note
x1 electrical connector

Note
Verify 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.

CAUTION
Do not damage any pins.
Install the bolts (x2) that attach the lower tub crossmember.
36 Nm (26.5 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Install the mid aero shield.

Note
x6 clips

Note
x3 bolts, 15 mm, 42 Nm; x5 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 Nm

Note
Apply Loctite 222 onto mid aero shield bolts, and then install fasteners.
Install the LH and RH wheels. See Wheel Assembly (Remove and Install).
Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
Connect MV power. See Disconnect MV Power.
Touch Stop Thermal Fluid Fill/Drain, and then touch Run. Allow the routine to complete.

Note
Touch Close once completed.
Touch Restore Bootloader Data after Perform CAN Redeploy, and the touch Run. Allow the routine to complete.

Note
Touch Close once completed.
Touch Restore Application Data, and then touch Run. Allow the routine to complete.

Note
Touch Close once completed.
Touch Coolant Air Purge, and then touch Run. Allow the routine to complete.
Touch Thermal System Performance Test, and then touch Run. Allow the routine to complete.

Note
Touch Close once completed.
Put stanchions around vehicle and set up a safety perimeter before performing the resolver error learn.

Note
Use 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.

Warning
Read the instructions thoroughly. Follow the appropriate safety precautions. Vehicle needs to be driven on a lift. Verify all wheels are clear of contacting ground.

Note
Vehicle software must be 2022.16.2 or later for routine to operate.
1. Start the routine, and then shift the vehicle into Drive.
2. Drive the vehicle on the lift until the desired speed is reached.
3. Vehicle will begin to coast down automatically.
4. Release the accelerator and allow vehicle to spin down.
  
  CAUTION
  Do not slam on the brakes.
5. When the axles have stopped spinning, shift the vehicle into Park.
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 bolts (x4) that attach the bed cargo tub lid.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
Recommend assistance

Note
Position the bed cargo tub lid onto the vehicle. Install the bolts that attach the bed cargo tub lid onto hinges.
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.

Note
Perform a validation test drive after repair.

Note
Drive 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.