Inverter - Front Drive Unit (Remove and Replace)
Correction code
3920048022
FRT
3.90
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.NOTE:
See Ergonomic Precautionsfor safe
and healthy working practices.
- 2025-08-11: Added caution not to damage lugs during removal.
- 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.
-
Verify FDU revision
NoteIf 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
-
Move vehicle onto lift
NoteEnsure positioning allows rear doors to open
- 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 vehicle into Service Mode Plus
using Vehicle Ops App
NoteVehicle Ops App > Login > Shared Fleet > Search VIN > Service Mode Plus
- Unlock the vehicle Gateway. See Gateway (Unlock).
-
Select 'Procedures'
NoteLighting Bolt Icon > High Voltage > Procedures
-
Select 'Front Drive Inverter
Replacement'
NoteProcedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
-
Select ‘Store Boot + App Data and start
fluid fill/drain’, click ‘Run’, and allow routine to complete
NoteSelect 'Close' once complete
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
- Disconnect MV power. See Disconnect MV Power (Modify).
- Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
- Remove leather over gloves and HV insulating gloves
-
Remove front aero shield
Note11x bolts, 10mm, 6 Nm
-
Remove front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
-
Remove LH front lower control arm aero
shield
Note3x bolts, 10mm, 7 Nm
-
Remove RH front lower control arm aero
shield
Note3x bolts, 10mm, 7 Nm
-
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
- Remove the LH and RH front wheel assemblies. See Wheels - Wheel (Remove and Install).
- Remove the frunk assembly. See Frunk Assembly (Remove and Install).
- Remove the front fascia assembly. See Front Fascia (Remove and Install).
-
Place coolant catcher below RH front of
vehicle
-
Disconnect radiator to manifold hose
from radiator and plug connections
Note1x spring clip, Remove from vehicle, Plug hoses
-
Place coolant catcher below LH front of
vehicle
-
Disconnect manifold to radiator hose
from radiator and plug connections
Note1x spring clips, Plug hoses
-
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
-
Disconnect CFM connectors
Note2x connectors, 2x clips
-
Remove upper CFM fasteners
Note2x bolts, 10mm, 10 Nm
-
Remove lower CFM fasteners
Note2x bolts, 10mm, 10 Nm
-
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
-
Remove powertrain return hose from FDU
and plug connections
Note1x spring clip, Release from heat exchanger, plug hose and exchanger
-
Disconnect powertrain return hose and
plug connections
Note1x spring clip, 1x mounting clip, plug hoses
-
Disconnect front steering actuator
Note4x connectors, Release locking tabs
-
Disconnect front drive unit breather
Note1x breather hose
-
Disconnect front drive unit harness
connector
Note1x connector, 1x harness clip, Release locking tab
-
Release front end harness from
subframe
Note2x stud clips
-
Remove LH front brake hose bracket
Note1x bolt, 10mm, 10 Nm
-
Remove LH front caliper and set
aside
Note2x bolts, 24mm, 315 Nm, Rotor will be loose until caliper is installed, Use lug nut to secure rotor as needed
-
Release LH chassis jumper harness from
knuckle
Note1x connector, 2x harness clips
-
Release LH front damper from lower
control arm
Note2x bolts, 21mm, 140 Nm, break bolts loose with breaker bar before using power tools
-
Remove nut securing LH front upper
control arm to knuckle
Note1x nut, 18mm, 85 Nm, Use step ladder as needed, the upper control arm is under tension, use caution when removing nut
-
Remove RH front brake hose bracket
Note1x bolt, 10mm, 10 Nm
-
Remove RH front caliper and set
aside
Note2x bolts, 24mm, 315 Nm, Rotor will be loose until caliper is installed
-
Release RH chassis jumper harness from
knuckle
Note1x connector, 2x harness clips
-
Release RH front damper from lower
control arm
Note2x bolts, 21mm, 140 Nm
-
Remove nut securing RH front upper
control arm to knuckle
Note1x nut, 18mm, 85 Nm, Use step ladder as needed, the upper control arm is under tension, use caution when removing nut
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
-
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 hoses and
plug connections
Note1x spring clips, 1x clips, Plug hoses
-
Release ground strap from HV Battery
chinstrap
Note1x bolt, 10mm, 10 Nm
-
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
-
Install subframe fixture to subframe
lifting tool
Notesecure fixture to lifting tool with at least two fasteners, bolts sizes will vary
-
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
-
Lower subframe from vehicle
NoteRecommend assistance, Watch for any missed connections or trapped harnesses when lowering
-
Disconnect air supply from subframe
lifting tool
-
Remove subframe lifting tool from under
vehicle
-
Disconnect inverter to heat exchanger
coolant hose
Note1x spring clip, Plug fittings, 1x mounting clip
-
Remove FDU supply hose
Note1x 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 front drive unit harness
Note1x connectors, 1x harness clips, Release locking tab, Release inverter connector lock then pivot lever out to release, move harness aside
-
Remove NVH cover
Note5x clips, Later models will come with Velcro cover
-
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 FDI from FDU
Note9x bolts, EP10, 12.5 Nm
-
Place drive inverter onto ESD mat
CAUTIONDo not damage or place face down on HV lugs, Careful not to damage the PCBA during removal
-
Remove ESD wrist strap from old
inverter
-
Install inverter 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
-
Prepare new drive inverter
NotePrepare new drive inverter, Save packaging to MRB old drive inverter, Remove any red protective covers
-
Secure ESD strap onto new inverter
housing
-
Wipe HV cable lugs to ensure contact
surfaces are free of debris
NoteAllow 1 minute dry time
-
Install FDI to FDU
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 ESD wrist strap from
inverter
-
Take 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 leak test adapter plug to 12V
connector at inverter - placeholder
-
Install leak test adapter to RDU HV
connector - placeholder
-
Connect regulator to adapter at HV
connector
-
Close both valves on the regulator test
tool
-
Connect regulator to air supply
-
Turn on regulator and open valve closest
to regulator
-
Set regulator to 1 psi
-
Open the 2nd valve to inject air into
the penthouse
NoteClose valve when pressure reaches 1 psi and stable
- Wait 45 seconds for pressure to settle
- Record start pressure valve
- Wait 60 seconds for test
-
Record end pressure valve
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.
-
Disconnect air supply from regulator
tool
-
Disconnect regulator from leak test
adapter at HV connector
-
Remove leak test adapter from HV
connector
-
Remove leak test adapter plug from 12V
connector at inverter - placeholder
-
Install RH DU mount
Note3x bolts, E14, 35 Nm + 55 degrees,
-
Install NVH cover
Note5x clips, Later models will come with Velcro cover
-
Secure front drive unit harness
Note1x connectors, 1x harness clips, 1x locking tab
-
Secure FDU supply hose
Note1x spring clips, 2x clips
-
Connect inverter coolant return
hose
Note1x spring clip, Remove plugs, One mounting clip
-
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
-
Disconnect air supply from subframe
lifting tool
-
Remove subframe lifting tool from under
vehicle
-
Remove subframe fixture to from lifting
tool
NoteRemove fixture from lifting tool, bolts sizes will vary
-
Connect powertrain supply hose
Note1x spring clips, 1x clips
-
Install ground strap to HV Battery
chinstrap
Note1x bolt, 10mm, 10 Nm
-
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
-
Install RH front lower control arm
aeroshield
Note3x bolts, 10mm, 7 Nm
-
Install LH lower control arm
shield
Note3x bolts, 10mm, 7 Nm
-
Install front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
-
Install front aero shield
Note11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
-
Secure RH front wheel liner to HV
battery chinstrap
Note1x push clip, 2x bolts, 10mm, 6 Nm
-
Install rear skid plate
Note6x 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
-
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 nut securing RH front upper
control arm to knuckle
Note1x nut, 18mm, 85 Nm, Use step stool as needed, Install new nut
-
Secure RH damper to lower control
arm
Note2x bolts, 21mm, 140 Nm
-
Install RH rear lower control arm
aeroshield
Note3x bolts, 10mm, 7 Nm
-
Secure RH chassis jumper harness to
knuckle
Note1x connector, 1x harness clips, Engage locking tab
-
Install RH front caliper
Note2x bolts, 24mm, 315 Nm
-
Install RH front brake hose
bracket
Note1x bolt, 10mm, 10 Nm
-
Secure LH damper to lower control
arm
Note2x bolts, 21mm, 140 Nm
-
Install LH lower control arm
shield
Note3x bolts, 10mm, 7 Nm
-
Secure LH chassis jumper harness to
knuckle
Note1x connectors, 2x harness clips, Engage locking tabs
-
Install LH front caliper
Note2x bolts, 24mm, 315 Nm, Rotor will be loose until caliper is installed, Use lug nut to secure rotor as needed
-
Install LH front brake hose
bracket
Note1x bolt, 10mm, 10 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
-
Connect powertrain return hose
Note1x spring clip, 1x mounting clip
-
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
-
Install lower CFM fasteners
Note2x bolts, 10mm, 10 Nm
-
Connect CFM connectors
Note2x connectors, Engage locking tab
-
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 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 front lower fascia
assembly
NoteEnsure no harnesses are pinched
-
Install RH fascia fastener and
connectors
Note1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Engage locking tab
-
Secure RH wheel liner
Note4x clips
-
Install LH fascia fastener
Note1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
-
Secure LH wheel liner
Note4x clips
-
Install front fascia fasteners and
covers
Note2x covers, 6x bolts, 10mm, 4 Nm, Install tow hook covers
-
Install front center applique
Note8x tabs, 1x connector, Ensure all tabs engage, Secure frunk release trigger connector
-
Install RH front wheel
Note6x nuts, 21mm, 205 Nm
-
Install LH front wheel
Note6x nuts, 21mm, 205 Nm
-
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, Use star pattern
-
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, Use star pattern
-
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
- Perform cooling system vacuum refill. See Cooling System (Vacuum Refill).
- 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
-
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
-
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
- Exit Service Mode. See Service Mode.
- 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