2025-05-15

Front Drive Inverter - Drive Inverter (Remove and Replace)

Correction code 3920048022 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2025-05-15: Update all steps to latest time study.
  • 2025-01-28: Added note at top of procedure to check for tri-motor front drive unit revision and replace entire front drive unit, if necessary. Updated entire procedure with latest validation steps.
  • 2024-12-18: Updated arc shield remove/install steps are for Tri Motor vehicles only.
  • 2024-12-11: Corrected air leak test valve sequence.
  • 2024-11-18: Updated note to reference only part numbers and not build date.
  • 2024-11-12: Added note to replace inverter mount with PN 1923000-XX-C for vehicles built before February 1, 2024.
  • 2024-09-18: Added steps for phase plugs and arc shield.
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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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Note
If the vehicle is tri-motor with a front drive unit that is revision -G or older, then replace the entire front drive unit with revision -H or newer. Refer to Front Drive Unit Assembly - Front Drive Unit (Remove and Replace). If the the vehicle is tri-motor with a front drive unit that is revision -H or newer, or if the vehicle is dual motor, then continue with this procedure.
  1. Verify FDU revision
    Informational PurposesAn informational icon, calling your attention
    Note
    If TM and FDU revision is -G or older then proceed to replace front drive unit, If TM and FDU revision is -H or newer then continue this procedure, If DM then skip this step
  2. Move vehicle onto lift
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    Note
    Ensure positioning allows rear doors to open
  3. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Set air suspension to "Jack Mode"
  4. Open LH front door
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    Note
    Push LH B-pillar door trigger to release
  5. Lower LH front window
  6. Open powered front trunk
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    Note
    Via exterior switch or UI
  7. Place vehicle into Service Mode Plus using Vehicle Ops App
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    Note
    Vehicle Ops App > Login > Shared Fleet > Search VIN > Service Mode Plus
  8. Unlock vehicle gateway
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    Note
    After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information
  9. Select 'Procedures'
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    Note
    Lighting Bolt Icon > High Voltage > Procedures
  10. Select 'Front Drive Inverter Replacement'
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    Note
    Procedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
  11. Select ‘Store Boot + App Data and start fluid fill/drain’, click ‘Run’, and allow routine to complete
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    Note
    Select 'Close' once complete
  12. Power down vehicle via UI
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    Note
    Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
  13. Remove rear underhood apron
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    Note
    9x clips
  14. Disconnect FRL connector then disconnect MV battery connector
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Release locking tab then disconnect FRL connector, Slide eCPA to left then lift lever to release MV battery connector, Early production trucks may have black FRL connector, Release eCPA by pushing down to unlock and slide red locking tab, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
  15. Verify operation of multimeter
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    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
  16. Raise vehicle fully
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    Note
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  17. Remove rear skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
  18. Remove all items from pockets and ensure not wearing metal items
  19. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  20. Put on HV insulating gloves and leather over gloves
  21. Verify no HV - Install amp clamp to RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  22. Remove leather over gloves and HV insulating gloves
  23. Remove front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 6 Nm
  24. Remove front skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
  25. Remove LH front lower control arm aero shield
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    Note
    3x bolts, 10mm, 7 Nm
  26. Remove RH front lower control arm aero shield
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    Note
    3x bolts, 10mm, 7 Nm
  27. Lower vehicle partially and set lift onto locks
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  28. Remove LH front wheel cap
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    Note
    1x cap, 8x clips, Use both hands to firmly pull wheel cap to release clips, Cap may remove with or without mounting ring attached
  29. Remove LH front wheel
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    Note
    6x nuts, 21mm, 205 Nm
  30. Remove RH front wheel cap
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    Note
    1x cap, 8x clips, Use both hands to firmly pull wheel cap to release clips, Cap may remove with or without mounting ring attached
  31. Remove RH front wheel
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    Note
    6x nuts, 21mm, 205 Nm
  32. Remove frunk assembly
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    Note
    6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Remove bolt covers from frunk floor, Remove washer fluid cap by gently prying upwards, Rotate bumpstops counter clockwise to release, the 25mm socket from PT Sensor kit can be used, Avoid straining emergency frunk release connector
  33. Remove front center applique
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    Note
    8x tabs, 1x connector, Release upper 4 tabs by pushing down then gently pull away, Release frunk release trigger connector
  34. Remove front fascia fasteners
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    Note
    2x covers, 6x bolts, 10mm, 4 Nm, Remove tow hook covers to expose bolts
  35. Release clips securing front portion of the LH front wheel house liner
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  36. Remove front fascia LH side fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
  37. Release clips securing front portion of the RH front wheel house liner
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  38. Remove front fascia RH side fastener and connectors
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    Note
    1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Pull red locking tab to release, Do not push down on locking tab
  39. Remove front lower fascia assembly
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    Note
    Place on suitable protective surface
  40. Place coolant catcher below RH front of vehicle
  41. Disconnect radiator to manifold hose from radiator and plug connections
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    Note
    1x spring clip, Remove from vehicle, Plug hoses
  42. Place coolant catcher below LH front of vehicle
  43. Disconnect manifold to radiator hose from radiator and plug connections
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clips, Plug hoses
  44. Release harness from CFM
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    Note
    1x grommet, 2x connectors, 5x harness clips, Pull red locking tab to disengage louver connector, Release temperature sensor then disconnect, Release grommet and pull harness through from frunk area
  45. Disconnect CFM connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, 2x clips
  46. Remove upper CFM fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  47. Remove lower CFM fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  48. Remove fore crossmember
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    Note
    2x bolts, 18mm, 90 Nm, Push up on CFM, Use hammer if needed, Recommend assistance
  49. Remove CFM
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Remove from below impact beam, Ensure harness is not pinched during removal
  50. Remove powertrain return hose from FDU and plug connections
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Release from heat exchanger, plug hose and exchanger
  51. Disconnect powertrain return hose and plug connections
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    Note
    1x spring clip, 1x mounting clip, plug hoses
  52. Disconnect front steering actuator
    Informational PurposesAn informational icon, calling your attention
    Note
    4x connectors, Release locking tabs
  53. Disconnect front drive unit breather
    Informational PurposesAn informational icon, calling your attention
    Note
    1x breather hose
  54. Disconnect front drive unit harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x harness clip, Release locking tab
  55. Release front end harness from subframe
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    Note
    2x stud clips
  56. Remove LH front brake hose bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  57. Remove LH front caliper and set aside
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 24mm, 315 Nm, Rotor will be loose until caliper is installed, Use lug nut to secure rotor as needed
  58. Release LH chassis jumper harness from knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x harness clips
  59. Release LH front damper from lower control arm
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 140 Nm, break bolts loose with breaker bar before using power tools
  60. Remove nut securing LH front upper control arm to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 18mm, 85 Nm, Use step ladder as needed, the upper control arm is under tension, use caution when removing nut
  61. Remove RH front brake hose bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  62. Remove RH front caliper and set aside
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 24mm, 315 Nm, Rotor will be loose until caliper is installed
  63. Release RH chassis jumper harness from knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x harness clips
  64. Release RH front damper from lower control arm
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 140 Nm
  65. Remove nut securing RH front upper control arm to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 18mm, 85 Nm, Use step ladder as needed, the upper control arm is under tension, use caution when removing nut
  66. Raise vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  67. Release RH front wheel liner from HV battery chinstrap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 2x bolts, 10mm, 6 Nm
  68. Position coolant drain container underneath RH front of HV battery
  69. Disconnect powertrain supply hoses and plug connections
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clips, 1x clips, Plug hoses
  70. Release ground strap from HV Battery chinstrap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  71. Remove bolt securing FDU HV harness to the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt
  72. Disconnect FDU HV harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged
  73. Install subframe fixture to subframe lifting tool
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    Note
    secure fixture to lifting tool with at least two fasteners, bolts sizes will vary
  74. Move the subframe lifting tool underneath the front subframe area
  75. Connect air supply to subframe lifting tool
  76. Secure lifting tool onto front subframe
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    Note
    Recommend assistance, Secure subframe to subframe lifting tool with straps,
  77. Position rear support posts onto FDU
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    Note
    Both FDU supports need to engage the FDU, The left side post is dimpled and fits into a recess on the FDU and the right side post has a teflon block that sits against the FDU, Both posts are threaded and the handle should be turned until the posts are tight
  78. Remove RH FDU mount bolt
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    Note
    1x bolt, E18, 85 Nm, Early production vehicles may have 16mm bolt
  79. Remove LH FDU mount bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
  80. Remove subframe bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 24mm, 220 Nm, 2x bolts, 21mm, 220 Nm, 4x bolts, 24mm, 215 Nm, Rearmost four bolts with stud have lower torque value of 215 Nm
  81. Lower subframe from vehicle
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    Note
    Recommend assistance, Watch for any missed connections or trapped harnesses when lowering
  82. Disconnect air supply from subframe lifting tool
  83. Remove subframe lifting tool from under vehicle
  84. Disconnect inverter to heat exchanger coolant hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug fittings, 1x mounting clip
  85. Remove FDU supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clips, 2x clips, NVH cover may need to be compressed for access to spring clip, Manipulate hose as required for removal, Plug open fittings
  86. Remove front drive unit harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connectors, 1x harness clips, Release locking tab, Release inverter connector lock then pivot lever out to release, move harness aside
  87. Remove NVH cover
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    Note
    5x clips, Later models will come with Velcro cover
  88. Remove RH FDU mount
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    Note
    3x bolts, E14, 35 Nm + 55 degrees,
  89. Remove label from phase cover
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    Note
    Discard label after removal
  90. Remove bolts securing phase out cover
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    Note
    2x bolts, EP10, 14 Nm
  91. Remove phase out cover
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    Note
    Use a plastic trim tool to aid in removal, If phase out cover or O-rings are damaged then replace with a new unit
  92. Remove phase plugs
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    Note
    3x plugs, Discard after removal, Firmly grip plug with needle nose pliers then pull outward, If plugs not present then skip this step
  93. Remove fasteners securing inverter to 3 phase lugs
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 11.5 Nm, 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
  94. Put on ESD wrist strap and secure it to inverter housing
  95. Remove FDI from FDU
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    Note
    9x bolts, EP10, 12.5 Nm
  96. Place drive inverter onto ESD mat
  97. Remove ESD wrist strap from old inverter
  98. Install inverter arc shield
    Informational PurposesAn informational icon, calling your attention
    Note
    If dual motor vehicle then skip this step, If FR4 arc shield material was present then it must be replaced with silicone arc shield during reassembly, If silicone arc shield material is present, replace it with a new silicone arc shield, FR4 material is rigid plastic, Silicone material is flexible
  99. Prepare new drive inverter
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    Note
    Prepare new drive inverter, Save packaging to MRB old drive inverter, Remove any red protective covers
  100. Secure ESD strap onto new inverter housing
  101. Wipe HV cable lugs to ensure contact surfaces are free of debris
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time
  102. Install FDI to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, EP10, 12.5 Nm, Fasteners can be reused
  103. Install fasteners securing inverter to the 3 phase lugs
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 11.5 Nm, 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
  104. Install phase out cover
    Informational PurposesAn informational icon, calling your attention
    Note
    If phase out cover or O-rings are damaged then replace with a new unit, If TM then updated phase out cover must be installed
  105. Install bolts securing phase out cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 14 Nm, Fasteners can be reused
  106. Install new label to phase cover
  107. Remove ESD wrist strap from inverter
  108. Take old inverter and prepare for MRB, Label properly for return or disposal
    Informational PurposesAn informational icon, calling your attention
    Note
    Use ESD wrist strap, Label inverter for MRB and return to packaging, Secure any protective red caps, Return or dispose of packaging through proper channels, Label the part as MRB
  109. Install leak test adapter plug to 12V connector at inverter - placeholder
  110. Install leak test adapter to RDU HV connector - placeholder
  111. Connect regulator to adapter at HV connector
  112. Close both valves on the regulator test tool
  113. Connect regulator to air supply
  114. Turn on regulator and open valve closest to regulator
  115. Set regulator to 1 psi
  116. Open the 2nd valve to inject air into the penthouse
    Informational PurposesAn informational icon, calling your attention
    Note
    Close valve when pressure reaches 1 psi and stable
  117. Wait 45 seconds for pressure to settle
  118. Record start pressure valve
  119. Wait 60 seconds for test
  120. Record end pressure valve
    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.
  121. Disconnect air supply from regulator tool
  122. Disconnect regulator from leak test adapter at HV connector
  123. Remove leak test adapter from HV connector
  124. Remove leak test adapter plug from 12V connector at inverter - placeholder
  125. Install RH DU mount
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E14, 35 Nm + 55 degrees,
  126. Install NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Later models will come with Velcro cover
  127. Secure front drive unit harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connectors, 1x harness clips, 1x locking tab
  128. Secure FDU supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clips, 2x clips
  129. Connect inverter coolant return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove plugs, One mounting clip
  130. Connect shop air supply to powertrain table
  131. Raise drive unit and subframe into position
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage components while raising subframe
  132. Install subframe bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 24mm, 220 Nm, 2x bolts, 21mm, 220 Nm, 4x bolts, 24mm, 215 Nm, Rearmost four bolts with stud have lower torque value of 215 Nm
  133. Install LH FDU mount bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
  134. Install RH FDU mount bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 85 Nm
  135. Disconnect air supply from subframe lifting tool
  136. Remove subframe lifting tool from under vehicle
  137. Remove subframe fixture to from lifting tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove fixture from lifting tool, bolts sizes will vary
  138. Connect powertrain supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clips, 1x clips
  139. Install ground strap to HV Battery chinstrap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  140. Secure FDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x bolt, 10mm, 10 Nm, Ensure no coolant or debris is present in connector housing at inverter or harness, Ensure locking tab is engaged
  141. Install RH front lower control arm aeroshield
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 7 Nm
  142. Install LH lower control arm shield
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 7 Nm
  143. Install front skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
  144. Install front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
  145. Secure RH front wheel liner to HV battery chinstrap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 2x bolts, 10mm, 6 Nm
  146. Install rear skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 to mid aero shield bolts and install fasteners
  147. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  148. Install nut securing RH front upper control arm to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 18mm, 85 Nm, Use step stool as needed, Install new nut
  149. Secure RH damper to lower control arm
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 140 Nm
  150. Install RH rear lower control arm aeroshield
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 7 Nm
  151. Secure RH chassis jumper harness to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x harness clips, Engage locking tab
  152. Install RH front caliper
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 24mm, 315 Nm
  153. Install RH front brake hose bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  154. Secure LH damper to lower control arm
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 140 Nm
  155. Install LH lower control arm shield
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 7 Nm
  156. Secure LH chassis jumper harness to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connectors, 2x harness clips, Engage locking tabs
  157. Install LH front caliper
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 24mm, 315 Nm, Rotor will be loose until caliper is installed, Use lug nut to secure rotor as needed
  158. Install LH front brake hose bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  159. Secure front end harness to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x stud clips
  160. Connect front drive unit breather
    Informational PurposesAn informational icon, calling your attention
    Note
    1x breather hose
  161. Connect front drive unit harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x harness clip, Engage locking tab
  162. Connect harness to steering rack
    Informational PurposesAn informational icon, calling your attention
    Note
    4x connector with locking tab
  163. Connect powertrain return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x mounting clip
  164. Install CFM
    Informational PurposesAn informational icon, calling your attention
    Note
    Install from bottom, Assistance recommend Manipulate as required, Ensure harness is not pinched during install
  165. Install fore crossmember
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 18mm, 90 Nm, Lift CFM away from beam to aid in clearance, Install beam by sliding rewards
  166. Install lower CFM fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  167. Connect CFM connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Engage locking tab
  168. Install upper CFM fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  169. Secure harness to CFM
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet, 2x connector, 1x harness clip, Secure grommet then connect temperature sensor, Engage locking tab on louver connector
  170. Connect radiator inlet coolant hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clips,Ensure hose is fully engaged with a push-pull-push test
  171. Connect radiator to manifold hose to radiator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Ensure hose is fully engaged with a push-pull-push test
  172. Install front lower fascia assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure no harnesses are pinched
  173. Install RH fascia fastener and connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Engage locking tab
  174. Secure RH wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  175. Install LH fascia fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
  176. Secure LH wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  177. Install front fascia fasteners and covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers, 6x bolts, 10mm, 4 Nm, Install tow hook covers
  178. Install front center applique
    Informational PurposesAn informational icon, calling your attention
    Note
    8x tabs, 1x connector, Ensure all tabs engage, Secure frunk release trigger connector
  179. Install RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    6x nuts, 21mm, 205 Nm
  180. Install LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    6x nuts, 21mm, 205 Nm
  181. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  182. Torque RH front wheel nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    6x nuts, 21mm, 205 Nm, Use star pattern
  183. Install RH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, 8x clips, Partially secure wheel cap to wheel, While partially installed wheel cover can be rotated to align with tire design, When aligned press inward from center of cap then secure all clips to mounting ring
  184. Torque LH front wheel nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    6x nuts, 21mm, 205 Nm, Use star pattern
  185. Install LH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, 8x clips, Partially secure wheel cap to wheel, While partially installed wheel cover can be rotated to align with tire design, When aligned press inward from center of cap then secure all clips to mounting ring
  186. Install vacuum refill cap onto coolant bottle assembly
  187. Place empty coolant container into front storage area
    Informational PurposesAn informational icon, calling your attention
    Note
    If frunk is not installed take caution, CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia
  188. Fill container with at least 15L of coolant
  189. Place filled coolant container onto coolant drain & fill cart
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle
  190. Setup coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  191. Install vacuum refill hose to refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully installed
  192. Position overflow hose into empty container
  193. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  194. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  195. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  196. Slowly open the refill valve to allow coolant to be drawn into the system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  197. Once the gauge reads zero, close the coolant refill valve
  198. Remove shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  199. Remove coolant refill hose from coolant container
  200. Remove coolant overflow hose from coolant container
  201. Remove vacuum refill hose from refill cap on coolant bottle
  202. Remove vacuum refill cap from coolant bottle assembly
  203. Remove coolant refill tool from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Move coolant drain & fill cart away from vehicle
  204. Remove coolant container from inside underhood area
  205. Connect FRL connector then connect MV battery connector
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Connect FRL connector then secure locking tab, Position lever to secure MV battery connector then slide eCPA to right, Early production trucks may have black FRL connector, If power cycling vehicle then ensure at least 60 seconds has passed since powering down
  206. Select 'Procedures'
    Informational PurposesAn informational icon, calling your attention
    Note
    Lighting Bolt Icon > High Voltage > Procedures
  207. Select 'Front Drive Inverter Replacement'
    Informational PurposesAn informational icon, calling your attention
    Note
    Procedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
  208. Select "Can redeploy," click "Run," and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select 'Close' once complete
  209. Run 'Coolant Air Purge' routine
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
  210. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required
  211. Install coolant bottle cap
  212. Run 'Thermal Performance' routine
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Front Drive Unit Replacement dashboard, Ensure result is 'Passed'
  213. Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn
    Informational PurposesAn informational icon, calling your attention
    Note
    Use safety stanchions to section off vehicle before driving vehicle on a lift
  214. Select 'Front Drive Inverter Replacement'
    Informational PurposesAn informational icon, calling your attention
    Note
    Procedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
  215. Run ODIN routine PROC_DIF_X_RESOLVER-ERROR-LEARNvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Resolver Error Learn
  216. Remove safety stanchions from around vehicle after resolver learn is completed
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove all stanchions after vehicle is finished with the resolver error learn
  217. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
  218. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
  219. Raise LH front window
  220. Close LH front door
  221. Review wheel alignment requirements and add correction code as needed