11/12/2024 14:34:57

Rear Drive Inverter - Drive Inverter (Remove and Replace)

Correction code 4020092022 FRT 3.72 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.

  • 2024-12-11: Corrected air leak test valve sequence.
  • 2024-11-20: Updated various torque values, added notes, and rearranged steps according to latest time study.
  • 2024-10-17: Updated bootloader steps and added note.
  • 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.
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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.
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Warning
Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.

Remove

  1. Open the LH front door and lower the LH front window.
  2. Open the tailgate.
  3. Open the tonneau cover.
  4. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  5. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  6. Unlock the vehicle Gateway. See Gateway (Unlock).
  7. Disconnect Toolbox and remove the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).
  8. On the vehicle touchscreen, navigate to Service Mode Plus > High Voltage > Procedures > Drive-Inverter-Replacement > Rear Drive Inverter Replacement > Store Boot + App Data and Start Fluid Fill/Drain, and then touch Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Close once completed.
  9. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  10. Disconnect MV power. See Disconnect MV Power.
  11. Remove the LH and RH rear wheel covers and loosen the lug nuts. See Wheel Assembly (Remove and Install).
  12. Remove the bed cargo tub lid. See Bed Cargo Tub - Bed Cargo Tub Lid (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to release the struts from the vehicle side. Only release the LH and RH struts from lid side.
  13. Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  14. Remove the LH and RH rear bed closeouts. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
  15. Remove the LH and RH tonneau water management seals. See Tailgate Seals - Tonneau Water Management Seal, LH, Center (Remove and Install).
  16. Remove the LH and RH upper bed side wall assemblies. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install).
  17. Remove the LH and RH bed side wall assemblies. See Bed Side Wall - Bed Side Wall - LH (Remove and Install).
  18. Remove the bed cargo smugglers bay. See Bed Cargo Tub - Bed Cargo Smugglers Bay (Remove and Install).
  19. Raise the vehicle to a comfortable working hight, and then remove the LH and RH rear wheels. Wheel Assembly (Remove and Install).
  20. Remove the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
  21. Remove the bolts (x2) that attach the lower tub crossmember.
    36 Nm (26.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  22. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
  23. Remove the leather over gloves and HV insulating gloves.
  24. Put the coolant drain below the rear inverter.
  25. Remove the coolant hose from the rear inverter lower fitting.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip, x1 hose clip
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug both ends using the plugs from the Coolant Hose Plug Kit (1135762-00-A).
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a long flathead screwdriver to release the clip on the hose, and then release the hose.
  26. Release the clip that attaches the Rear Drive Unit (RDU) LV harness clip.
  27. Release the clips (x2) that attach the lower portion of the rear inverter acoustic cover.
  28. Remove the bolts (x4) that attach the RDU HV harness bracket.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T30 socket
  29. Lower the vehicle until the tires are touching the ground.
  30. Put the coolant catcher below the RDU.
  31. Release the clips (x5) that attach the acoustic cover surrounding the RH motor mount.
  32. Remove the coolant hose from the rear inverter upper fitting.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug both ends after disconnecting the hose with plugs from the Coolant Hose Plug Kit (1135762-00-A).
  33. Release the clip that attaches the rear inverter coolant hose to the gearbox housing.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the hose away from the inverter.
  34. Remove the coolant catcher from below the vehicle.
  35. Disconnect the RDU HV cable from the RDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Disengage the locking tab, and then release the connector body and move it aside.
  36. Disconnect the RDU logic electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not get coolant ingress into this electrical connector. Move aside as needed.
  37. Release the RDU LV harness clip.
  38. Remove the bolt that attaches the ground strap the RDU.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    Figure 1. Dual Motor Vehicles
    Figure 2. Tri-Motor Vehicles
  39. Remove the label to access the phase out cover bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Label is a one time use only. Discard the label after removal.
  40. Remove the bolts (x2) that attach the phase out cover.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  41. Remove the phase out cover assembly.
    Informational PurposesAn informational icon, calling your attention
    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.
  42. Remove the bolts (x3) that attach the 3 phase busbars to the drive inverter.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket (magnetic)
  43. Release the clips (x5) that attach the acoustic cover surrounding the RH motor mount.
  44. Position a floor jack to support the RDU.
  45. Break the RH motor mount bolt loose.
    85 Nm (62.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles may be equipped with a 16 mm bolt or a Torx E18 bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x NVH mass, Revision D subframe will not have NVH mass. 16 mm hex bolts cannot be used on Revision D subframe. E18 bolts can be used on all subframes. If mass present then mass must be reinstalled.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Insert the breaker bar from the RH side wheel well to access the bolt.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 16 mm socket or External Torx E18
    • 2 in extension
    • Breaker bar
  46. Remove the bolts (x3) that attach the RH motor mount assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque: 35 Nm + 55 degrees
  47. Remove the bolt that attaches the RH motor mount.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 85 Nm, 1x NVH mass. Revision D subframe will not have NVH mass. 16 mm hex bolts cannot be used on Revision D subframe. E18 bolts can be used on all subframes, If mass present then mass must be reinstalled.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E18
  48. Remove the RH rear motor mount assembly from the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Acoustic cover sits between the RH rear motor mount and the rear subframe.
  49. Put on the ESD wrist strap and secure it to the inverter housing.
  50. Remove the bolts (x9) that attach the drive inverter to the RDU gearbox assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque 6 Nm + 20 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Bolts can be reused.
  51. Remove the drive inverter from the RDU, and then drain the coolant from the inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Gasket is a one time use only.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid damage to the printed circuit board.
  52. Put the drive inverter on the ESD mat.
  53. Remove the ESD wrist strap from the old inverter.

Install

  1. Prepare the new drive inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Save the packaging to MRB the old drive inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove any red protective covers.
  2. Secure the ESD strap on the new drive inverter housing.
  3. Clean the HV cable lugs with an Isopropyl Alcohol (IPA) wipe to ensure the contact surfaces are free of debris.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time.
  4. Position the drive inverter to the RDU, and then hand tighten the bolt.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand tight first. Bolt tightening will be performed later in this procedure.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 guide pins
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the drive inverter into position.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage the circuit board when maneuvering near the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Thread in bolt to hold the drive inverter in place.
  5. Thread in and flush the bolts (x9) that attach the drive inverter to the rear gearbox assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
    Informational PurposesAn informational icon, calling your attention
    Note
    Bolts can be reused.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand tighten first. Tighten sequence in next step.
  6. Torque the fasteners that attach the inverter to the gearbox assembly.
    12.5 Nm (9.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque the two fasteners nearest alignment dowels first.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  7. Install the bolts (x3) that attach the drive inverter to the 3 phase lugs.
    11.5 Nm (8.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket (magnetic)
    Informational PurposesAn informational icon, calling your attention
    Note
    Fasteners should be reused. If fasteners need to be replaced then follow torque sequence - tighten to 12.5 Nm then reverse 180 degrees then tighten to 5 Nm.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all bolts are accounted for.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a magnet, as needed.
  8. Install the bolts (x2) that attach the RDU phase out cover.
    14 Nm (10.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  9. Install a new phase out cover warning label.
  10. Remove the ESD wrist strap from the drive inverter.
  11. Take the old drive inverter and prepare for MRB. Label properly for return or disposal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use ESD wrist strap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Label the drive inverter for MRB and return to packaging.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure any protective red caps.
    Informational PurposesAn informational icon, calling your attention
    Note
    Return or dispose of packaging through proper channels.
  12. Install the leak test adapter plug (1450875-00-A) to the electrical connector at the drive inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the surfaces are clean, free debris, and the adapter is fully seated otherwise a false test failure may occur.
  13. Install the leak test adapter to the RDU HV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the surfaces are clean, free debris, and the adapter is fully seated otherwise a false test failure may occur.
  14. Connect a regulator to adapter (1026636-00-A) at the HV electrical connector.
  15. Close both valves on the regulator test tool
  16. Connect regulator to air supply
  17. Open inlet valve on regulator valve
  18. Set regulator to 1 psi
  19. Open the outlet valve
  20. Wait 45 seconds for pressure to settle
  21. Close the inlet valve
  22. Record value of starting pressure
  23. Wait 60 seconds for test
  24. Record value of end pressure
    Informational PurposesAn informational icon, calling your attention
    Note
    If pressure did not drop more than 0.04 psi, continue to next step. If pressure dropped more than 0.04 psi, then inspect for leaks.
  25. Close both valves
  26. Disconnect air supply from regulator tool
  27. Disconnect the regulator from the leak test adapter at the HV electrical connector.
  28. Remove the leak test adapter from the HV electrical connector.
  29. Remove the leak test adapter plug from the electrical connector at the drive inverter.
  30. Position the RH side motor mount with the acoustic cover into the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver between the RDU and the rear subframe.
  31. Hand tighten the bolts (x4) that attach the RH rear motor mount to the drive inverter and the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E14
    • External Torx E18
    Informational PurposesAn informational icon, calling your attention
    Note
    Tightening of the bolts at the next steps.
  32. Tighten the bolts (x4) that attach the RH motor mount to the RDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque: 35 Nm + 55 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Follow the torque sequence shown.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E14
  33. Tighten the RH rear motor mount bolt to the rear subframe.
    85 Nm (62.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    1x NVH mass, Revision D subframe will not have NVH mass. 16 mm hex bolts cannot be used on Revision D subframe. E18 bolts can be used on all subframes. If mass present then mass must be reinstalled.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles may be equipped with a 16 mm bolt or a Torx E18 bolt.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Insert the torque wrench from the RH side wheel well to access the bolt.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 16 mm socket or External Torx E18
    • 2 in extension
  34. Remove the jack stand from supporting the RDU.
  35. Secure the RH side acoustic cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    x5 clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the above clips and remaining from below.
  36. Install the bolt that attaches the ground strap to the RDU.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
  37. Secure the RDU electrical harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip
  38. Connect the HV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage the locking tab.
  39. Position the coolant catcher below the RDU.
  40. Secure the rear inverter coolant hose to the gearbox housing.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 hose clip
  41. Install the coolant hose onto the rear inverter upper fitting.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove plugs from both ends.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull test.
  42. Fully raise the vehicle.
  43. Secure the lower acoustic cover clips (x2).
  44. Secure the RDU electrical harness clip.
  45. Connect the RDU logic electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that the lever is fully engaged.
  46. Put the coolant drain below the drive inverter.
  47. Install the coolant hose onto the drive inverter lower fitting.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plugs from both ends.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test.
  48. Remove the coolant drain container from underneath the vehicle.
  49. Install the bolts (x4) that attach the RDU HV harness bracket.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T30 socket
  50. Secure the RDU header connector to the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 electrical connector
    Informational PurposesAn informational icon, calling your attention
    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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any pins.
  51. Install the bolts (x2) that attach the lower tub crossmember.
    36 Nm (26.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  52. Install the mid aero shield. See Undertray - Mid Aeroshield (Remove and Install).
  53. Install the LH and RH wheels. See Wheel Assembly (Remove and Install).
  54. Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
  55. Reconnect MV power. See Disconnect MV Power.
  56. On the vehicle touchscreen, touch Stop Thermal Fluid Fill/Drain, touch Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Close once completed.
  57. Run ODIN routine PROC_PMR_X_RESTORE-DATA-BOOT-AND-WRITE-DRIVE-TYPEvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Bootloader Data
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Bootloader Data
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Bootloader Data
  58. Run ODIN routine PROC_DIR_X_RESTORE-DATA-APPvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Application Data
  59. Run ODIN routine PROC_EGGRIGHT3_X_THERMAL-COOLANT-AIR-PURGE-STARTvia Toolbox: (link)via Service Mode Plus:
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
  60. Run ODIN routine TEST-SELF_EGGRIGHT3_X_THERMAL-PERFORMANCEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
  61. Put stanchions around vehicle and set up a safety perimeter before performing the resolver error learn.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use safety stanchions to section off the vehicle before driving the vehicle on the lift.
  62. Partially raise the vehicle.
  63. Run ODIN routine PROC_DIR_X_RESOLVER-ERROR-LEARNvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Resolver Error Learn
  64. Remove the safety stanchions from around vehicle after the resolver learn is completed.
  65. Install the bed cargo smugglers bay. See Bed Cargo Tub - Bed Cargo Smugglers Bay (Remove and Install).
  66. Install the LH and RH bed side walls. See Bed Side Wall - Bed Side Wall - LH (Remove and Install).
  67. Install the LH and RH rear bed closeouts. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
  68. Install the LH and RH upper bed side wall assemblies. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install)
  69. Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  70. Install the bed cargo tub lid. See Bed Cargo Tub - Bed Cargo Tub Lid (Remove and Replace).
  71. Install the bed cargo tub struts. See Tonneau - Bed Cargo Tub Strut (Remove and Install).
  72. Close the tailgate.
  73. Close the tonneau cover.
  74. Raise the LH front window and close the LH front door.
  75. Perform a test drive.
    Informational PurposesAn informational icon, calling your attention
    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.