2025-01-28
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 LaborTimeFeedback@tesla.com.
NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 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.
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.
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.
Remove
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
- Open the LH front door and lower the LH front window.
- Open the powered frunk.
- Place the vehicle into Service Mode. See Service Mode.
- Unlock the vehicle Gateway. See Gateway (Unlock).
- On the vehicle touchscreen, navigate to Service Mode PlusHigh VoltageProceduresFront Drive Inverter Replacement.
-
Touch Store Boot + App Data and Start Fluid
Fill/Drain, and then touch Run. Allow routine to
complete.
NoteTouch Close once completed.
- Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Disconnect MV power. See Disconnect MV Power (Modify).
- Remove the frunk assembly. See Frunk Assembly (Remove and Install).
- Remove the front fascia. See Front Bumper Fascia - Front Fascia (Remove and Install).
- Put a coolant catcher below the RH front of the vehicle.
-
Disconnect radiator to manifold hose
from radiator and plug connections
Note1x spring clip, Remove from vehicle, Plug hoses
-
Disconnect manifold to radiator hose
from radiator and plug connections
Note1x spring clips, Plug hoses
-
Disconnect powertrain return hose from
supermanifold
Note1x spring clip, Plug open fitting
-
Disconnect powertrain return
hose
Note1x spring clip, 1x mounting clip
-
Release harness from CFM
Note1x 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
-
Remove upper CFM fasteners
Note2x bolts, 10mm, 10 Nm
-
Remove LH front wheel cap
Note1x cap, 8x clips, Use both hands to firmly pull wheel cap to release clips, Cap may remove with or without mounting ring attached
-
Loosen LH front wheel nuts
Note6x nuts, 21mm, 205 Nm
-
Remove RH front wheel cap
Note1x cap, 8x clips, Use both hands to firmly pull wheel cap to release clips, Cap may remove with or without mounting ring attached
-
Loosen RH front wheel nuts
Note6x nuts, 21mm, 205 Nm
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
-
Remove front aero shield
Note11x bolts, 10mm, 6 Nm
-
Remove mid aero shield
Note6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
- Remove all items from pockets and ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck 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
- Put on HV insulating gloves and leather over gloves
-
Verify no HV - Install amp clamp to
RDU HV harness
NoteVerify 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
- Remove leather over gloves and HV insulating gloves
-
Remove bolt securing FDU HV harness to
the FDU
Note1x bolt
-
Disconnect FDU HV harness
connector
Note1x 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
-
Release RH front wheel liner from HV
battery chinstrap
Note1x push clip, 2x bolts, 10mm, 6 Nm
- Position coolant drain container underneath RH front of HV battery
-
Disconnect powertrain supply and
return hoses
Note2x spring clips, 2x clips, Plug hoses
-
Disconnect CFM connectors
Note2x connectors, 2x clips
-
Remove fore crossmember
Note2x bolts, 18mm, 90 Nm, Push up on CFM, Use hammer if needed, Recommend assistance
-
Remove CFM
NoteRecommend assistance, Remove from below impact beam, Ensure harness is not pinched during removal
-
Lower vehicle partially and set lift
onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Disconnect front steering
actuator
Note4x connectors, Release locking tabs
-
Disconnect front drive unit breather
Note1x breather hose
-
Release front end harness from
subframe
Note2x stud clips
-
Remove LH front wheel
Note6x nuts, 21mm, 205 Nm
-
Remove LH front lower control arm
shield
Note3x bolts, 10mm, 7 Nm
-
Remove RH front wheel
Note6x nuts, 21mm, 205 Nm
-
Remove RH front lower control arm
aeroshield
Note3x bolts, 10mm, 7 Nm
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
- Move the subframe lifting tool underneath the front subframe area
- Connect air supply to subframe lifting tool
-
Secure lifting tool onto front
subframe
NoteRecommend assistance, Secure subframe to subframe lifting tool with straps,
-
Position rear support posts onto
FDU
NoteBoth 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
-
Remove RH FDU mount bolt
Note1x bolt, E18, 85 Nm, Early production vehicles may have 16mm bolt
-
Remove LH FDU mount bolt
Note1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
-
Remove subframe bolts
Note2x 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
-
Partially Lower subframe
NoteLower subframe to allow access to RH DI mount and bolts, support subframe with fixture, NVH cover removed for clarity
-
Disconnect inverter to heat exchanger
coolant hose
Note1x spring clip, Plug fittings, 1x mounting clip
-
Remove PT return hose
Note1x cable tie, 1x spring clip, 2x edge clips, Cut cable tie and discard if present, Manipulate hose as required for removal, Plug open fitting
-
Remove FDU supply hose
Note2x 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
-
Remove NVH pad
Note7x clips, Revisions may be secured by velcro
-
Remove RH FDU mount
Note3x bolts, E14, 35 Nm + 55 degrees,
-
Remove label from phase cover
NoteDiscard label after removal
-
Remove bolts securing phase out
cover
Note2x bolts, EP10, 14 Nm
-
Remove phase out cover
NoteUse a plastic trim tool to aid in removal, If phase out cover or O-rings are damaged then replace with a new unit
-
Remove phase plugs
Note3x plugs, Discard after removal, Firmly grip plug with needle nose pliers then pull outward, If plugs not present then skip this step
-
Remove fasteners securing inverter to
3 phase lugs
Note3x 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
- Put on ESD wrist strap and secure it to inverter housing
-
Remove fasteners securing FDI
Note9x bolts, EP10, 12.5 Nm, Remaining bolts will be removed at a later step
-
Remove FDI
NoteRemove inverter through right side opening between subframe and body
-
Remove inverter arc shield
NoteIf dual motor vehicle then skip this step, Discard after removal, If FR4 arc shield material present 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 during re-assembly, FR4 material is rigid plastic, Silicone material is flexible
- Place the drive inverter onto the ESD mat.
- Remove the ESD wrist strap from the old inverter.
Install
-
Prepare the new inverter.
NoteSave packaging to MRB the old inverter.NoteRemove any red protective covers.
- Secure the ESD strap onto the new inverter housing.
-
Wipe the HV cable lugs to ensure
contact surfaces are free of debris with an Isopropyl Alcohol (IPA) wipe.
NoteAllow 1 minute dry time.
-
For Tri Motor front drive inverter
only: install new silicone arc shield.
NoteIf 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
-
Install FDI
NoteInsert inverter through right side opening between subframe and body, Use caution to avoid damaging busbars,
-
Install fasteners securing inverter to
3 phase lugs
Note9x bolts, EP10, 12.5 Nm, Fasteners can be reused
-
Install fasteners securing inverter to
the 3 phase lugs
Note3x 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
-
Install phase out cover
NoteIf phase out cover or O-rings are damaged then replace with a new unit, If TM then updated phase out cover must be installed
-
Install bolts securing phase out
cover
Note2x bolts, EP10, 14 Nm, Fasteners can be reused
- Install new label to phase cover
- Remove the ESD wrist strap from the inverter.
-
Take the old inverter and prepare for
MRB. Label properly for return or disposal.
NoteUse 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.
- Install the leak test adapter plug to 12V connector at inverter - placeholder
- Install the leak test adapter to the HV connector - placeholder
- Connect regulator to adapter at the HV connector.
- Close both valves on the regulator test tool
- Connect regulator to air supply
- Open inlet valve on regulator valve
- Set regulator to 1 psi
- Open the outlet valve
- Wait 45 seconds for pressure to settle
- Close the inlet valve
- Record value of starting pressure
- Wait 60 seconds for test
-
Record value of end pressure
NoteIf 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.
- Close both valves
- Disconnect air supply from regulator tool
- Disconnect regulator from leak test adapter at the HV connector.
- Remove leak test adapter from the HV connector.
- Remove the leak test adapter plug from 12V connector at inverter - placeholder
-
Install RH DU mount
Note3x bolts, E14, 35 Nm + 55 degrees,
-
Secure NVH cover
Note6x ball and socket clips
-
Install PT return hose
Note1x cable tie, 1x spring clip, 2x edge clips, Manipulate hose as required for install, Install cable tie and trim flush if present during removal, Perform a push-pull-push test to ensure hose is engaged, Remove plug
-
Position FDU supply hose onto
subframe
Note2x clips, Hose will be connected at a later step
-
Connect inverter coolant inlet
hose
Note1x spring clip, Remove plugs
-
Connect inverter coolant return
hose
Note1x spring clip, Remove plugs, One mounting clip
-
Connect FDU logic connector
Note1x connector, Ensure no coolant or debris is present in connector housing at inverter or harness, Pivot locking arm up to secure
- Connect shop air supply to powertrain table
-
Raise drive unit and subframe into
position
NoteUse caution to not damage components while raising subframe
-
Install subframe bolts
Note2x 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
-
Install LH FDU mount bolt
Note1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
-
Install RH FDU mount bolt
Note1x bolt, E18, 85 Nm
- Remove subframe lifting tool from under vehicle
- Disconnect air supply from subframe lifting tool
-
Secure FDU HV harness
Note1x 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
-
Connect powertrain supply and return
hoses
Note2x spring clips, 2x clips, Remove plugs from hoses
-
Lower vehicle partially and set lift
onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Install RH front lower control arm
aeroshield
Note3x bolts, 10mm, 7 Nm
-
Install RH front wheel
Note6x nuts, 21mm, 205 Nm
-
Install LH lower control arm
shield
Note3x bolts, 10mm, 7 Nm
-
Install LH front wheel
Note6x nuts, 21mm, 205 Nm
-
Secure front end harness to
subframe
Note2x stud clips
-
Connect front drive unit breather
Note1x breather hose
-
Connect front drive unit harness
connector
Note1x connector, 1x harness clip, Engage locking tab
-
Connect harness to steering rack
Note4x connector with locking tab
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
-
Install CFM
NoteInstall from bottom, Assistance recommend Manipulate as required, Ensure harness is not pinched during install
-
Install fore crossmember
Note2x bolts, 18mm, 90 Nm, Lift CFM away from beam to aid in clearance, Install beam by sliding rewards
-
Connect CFM connectors
Note2x connectors, Engage locking tab
-
Secure RH front wheel liner to HV
battery chinstrap
Note1x push clip, 2x bolts, 10mm, 6 Nm
- Install the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
- Install the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Torque RH front wheel nuts
Note6x nuts, 21mm, 205 Nm
-
Install RH front wheel cap
Note1x 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
-
Torque LH front wheel nuts
Note6x nuts, 21mm, 205 Nm
-
Install LH front wheel cap
Note1x 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
-
Install upper CFM fasteners
Note2x bolts, 10mm, 10 Nm
-
Secure harness to CFM
Note1x grommet, 2x connector, 1x harness clip, Secure grommet then connect temperature sensor, Engage locking tab on louver connector
-
Connect powertrain return hose
Note1x spring clip, 1x mounting clip
-
Connect powertrain supply hose to
supermanifold
Note1x spring clip, Plug hose
-
Connect radiator inlet coolant
hose
Note1x spring clips,Ensure hose is fully engaged with a push-pull-push test
-
Connect radiator to manifold hose to
radiator
Note1x spring clip, Ensure hose is fully engaged with a push-pull-push test
- Install the front fascia, but do not install the frunk assembly or rear underhood apron yet. See Front Bumper Fascia - Front Fascia (Remove and Install).
- Install vacuum refill cap onto coolant bottle assembly
-
Place empty coolant container into
front storage area
NoteIf 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
- Fill container with at least 15L of coolant
-
Place filled coolant container onto
coolant drain & fill cart
NoteDo not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle
-
Setup coolant refill tool
NoteVerify all valves on refill tool are in the closed position, See image for clarity
-
Install vacuum refill hose to refill
cap on coolant bottle
NotePerform push-pull-push test to verify hose is fully installed
- Position overflow hose into empty container
-
Place refill hose inside filled
coolant container
NoteMake sure hose end is fully submerged into coolant
-
Connect shop air supply to coolant
refill tool
NoteIf not already done, Verify refill valve is set to off
-
Open air inlet valve to draw a vacuum,
Once gauge stabilizes, Fully close valve
NoteGauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
-
Slowly open the refill valve to allow
coolant to be drawn into the system
NoteMake sure hose end of refill hose is fully submerged during entire process
- Once the gauge reads zero, close the coolant refill valve
-
Remove shop air supply to coolant
refill tool
NoteIf not already done, Verify refill valve is set to off
- Remove coolant refill hose from coolant container
- Remove coolant overflow hose from coolant container
- Remove vacuum refill hose from refill cap on coolant bottle
- Remove vacuum refill cap from coolant bottle assembly
-
Remove coolant refill tool from
vehicle
NoteMove coolant drain & fill cart away from vehicle
- Remove coolant container from inside underhood area
- Reconnect MV power. See Disconnect MV Power (Modify).
-
Select 'Procedures'
NoteLighting Bolt Icon > High Voltage > Procedures
-
Select 'Front Drive Inverter
Replacement'
NoteProcedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
-
Run ODIN routine
PROC_PMF_X_RESTORE-DATA-BOOT-AND-WRITE-DRIVE-TYPEvia Toolbox: (link)via Service Mode Plus:
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Restore Bootloader Data
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Restore Bootloader Data
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Restore Bootloader Data
-
Select "Can redeploy," click "Run,"
and allow routine to complete
NoteSelect 'Close' once complete
-
Run 'Coolant Air Purge' routine
NoteTouch 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
-
Inspect coolant level and top off as
necessary
NoteEnsure that the fluid level is at the Max line, Top off fluid as required
- Install coolant bottle cap
-
Run 'Thermal Performance'
routine
NoteVia Front Drive Unit Replacement dashboard, Ensure result is 'Passed'
-
Place stanchions around vehicle and
set up a safety perimeter before performing resolver error learn
NoteUse safety stanchions to section off vehicle before driving vehicle on a lift
-
Raise vehicle partially and lower lift
onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Select 'Procedures'
NoteLighting Bolt Icon > High Voltage > Procedures
-
Select 'Front Drive Inverter
Replacement'
NoteProcedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
- Run ODIN routine PROC_DIF_X_RESOLVER-ERROR-LEARNvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Resolver Error Learn
-
Remove safety stanchions from around
vehicle after resolver learn is completed
NoteRemove all stanchions after vehicle is finished with the resolver error learn
- Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
- Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
- Raise the LH front window and close the LH front door.
- Review wheel alignment requirements and add correction code as needed