2025-10-07

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.

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.

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 Drive Unit - Front (Remove and Replace). If 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.

Verify FDU revision

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
Move vehicle onto lift

Note
Ensure 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

Note
Vehicle Ops App > Login > Shared Fleet > Search VIN > Service Mode Plus
Unlock the vehicle Gateway. See Gateway (Unlock).
Select 'Procedures'

Note
Lighting Bolt Icon > High Voltage > Procedures
Select 'Front Drive Inverter Replacement'

Note
Procedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
Select ‘Store Boot + App Data and start fluid fill/drain’, click ‘Run’, and allow routine to complete

Note
Select '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

Note
11x bolts, 10mm, 6 Nm
Remove front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Remove LH front lower control arm aero shield

Note
3x bolts, 10mm, 7 Nm
Remove RH front lower control arm aero shield

Note
3x bolts, 10mm, 7 Nm
Lower vehicle partially and set lift onto locks

Note
Raise 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

Note
1x 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

Note
1x spring clips, Plug hoses
Release harness from CFM

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
Disconnect CFM connectors

Note
2x connectors, 2x clips
Remove upper CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Remove lower CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Remove fore crossmember

Note
2x bolts, 18mm, 90 Nm, Push up on CFM, Use hammer if needed, Recommend assistance
Remove CFM

Note
Recommend assistance, Remove from below impact beam, Ensure harness is not pinched during removal
Remove powertrain return hose from FDU and plug connections

Note
1x spring clip, Release from heat exchanger, plug hose and exchanger
Disconnect powertrain return hose and plug connections

Note
1x spring clip, 1x mounting clip, plug hoses
Disconnect front steering actuator

Note
4x connectors, Release locking tabs
Disconnect front drive unit breather

Note
1x breather hose
Disconnect front drive unit harness connector

Note
1x connector, 1x harness clip, Release locking tab
Release front end harness from subframe

Note
2x stud clips
Remove LH front brake hose bracket

Note
1x bolt, 10mm, 10 Nm
Remove LH front caliper and set aside

Note
2x 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

Note
1x connector, 2x harness clips
Release LH front damper from lower control arm

Note
2x bolts, 21mm, 140 Nm, break bolts loose with breaker bar before using power tools
Remove nut securing LH front upper control arm to knuckle

Note
1x 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

Note
1x bolt, 10mm, 10 Nm
Remove RH front caliper and set aside

Note
2x bolts, 24mm, 315 Nm, Rotor will be loose until caliper is installed
Release RH chassis jumper harness from knuckle

Note
1x connector, 2x harness clips
Release RH front damper from lower control arm

Note
2x bolts, 21mm, 140 Nm
Remove nut securing RH front upper control arm to knuckle

Note
1x nut, 18mm, 85 Nm, Use step ladder as needed, the upper control arm is under tension, use caution when removing nut
Raise vehicle fully

Note
Set 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

Note
1x push clip, 2x bolts, 10mm, 6 Nm
Position coolant drain container underneath RH front of HV battery
Disconnect powertrain supply hoses and plug connections

Note
1x spring clips, 1x clips, Plug hoses
Release ground strap from HV Battery chinstrap

Note
1x bolt, 10mm, 10 Nm
Remove bolt securing FDU HV harness to the FDU

Note
1x bolt
Disconnect FDU HV harness connector

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
Install subframe fixture to subframe lifting tool

Note
secure 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

Note
Recommend assistance, Secure subframe to subframe lifting tool with straps,
Position rear support posts onto FDU

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
Remove RH FDU mount bolt

Note
1x bolt, E18, 85 Nm, Early production vehicles may have 16mm bolt
Remove LH FDU mount bolt

Note
1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
Remove subframe bolts

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
Lower subframe from vehicle

Note
Recommend 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

Note
1x spring clip, Plug fittings, 1x mounting clip
Remove FDU supply hose

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
Remove front drive unit harness

Note
1x connectors, 1x harness clips, Release locking tab, Release inverter connector lock then pivot lever out to release, move harness aside
Remove NVH cover

Note
5x clips, Later models will come with Velcro cover
Remove RH FDU mount

Note
3x bolts, E14, 35 Nm + 55 degrees,
Remove label from phase cover

Note
Discard label after removal
Remove bolts securing phase out cover

Note
2x bolts, EP10, 14 Nm
Remove phase out cover

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
Remove phase plugs

Note
3x 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

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
Put on ESD wrist strap and secure it to inverter housing
Remove FDI from FDU

Note
9x bolts, EP10, 12.5 Nm
Place drive inverter onto ESD mat

CAUTION
Do 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

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
Prepare new drive inverter

Note
Prepare 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

Note
Allow 1 minute dry time
Install FDI to FDU

Note
9x bolts, EP10, 12.5 Nm, Fasteners can be reused
Install fasteners securing inverter to the 3 phase lugs

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
Install phase out cover

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
Install bolts securing phase out cover

Note
2x 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

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
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

Note
Close 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

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.
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

Note
3x bolts, E14, 35 Nm + 55 degrees,
Install NVH cover

Note
5x clips, Later models will come with Velcro cover
Secure front drive unit harness

Note
1x connectors, 1x harness clips, 1x locking tab
Secure FDU supply hose

Note
1x spring clips, 2x clips
Connect inverter coolant return hose

Note
1x spring clip, Remove plugs, One mounting clip
Connect shop air supply to powertrain table
Raise drive unit and subframe into position

Note
Use caution to not damage components while raising subframe
Install subframe bolts

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
Install LH FDU mount bolt

Note
1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
Install RH FDU mount bolt

Note
1x 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

Note
Remove fixture from lifting tool, bolts sizes will vary
Connect powertrain supply hose

Note
1x spring clips, 1x clips
Install ground strap to HV Battery chinstrap

Note
1x bolt, 10mm, 10 Nm
Secure FDU HV harness

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
Install RH front lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
Install LH lower control arm shield

Note
3x bolts, 10mm, 7 Nm
Install front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Install front aero shield

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
Secure RH front wheel liner to HV battery chinstrap

Note
1x push clip, 2x bolts, 10mm, 6 Nm
Install rear skid plate

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
Lower vehicle partially and set lift onto locks

Note
Raise 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

Note
1x nut, 18mm, 85 Nm, Use step stool as needed, Install new nut
Secure RH damper to lower control arm

Note
2x bolts, 21mm, 140 Nm
Install RH rear lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
Secure RH chassis jumper harness to knuckle

Note
1x connector, 1x harness clips, Engage locking tab
Install RH front caliper

Note
2x bolts, 24mm, 315 Nm
Install RH front brake hose bracket

Note
1x bolt, 10mm, 10 Nm
Secure LH damper to lower control arm

Note
2x bolts, 21mm, 140 Nm
Install LH lower control arm shield

Note
3x bolts, 10mm, 7 Nm
Secure LH chassis jumper harness to knuckle

Note
1x connectors, 2x harness clips, Engage locking tabs
Install LH front caliper

Note
2x 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

Note
1x bolt, 10mm, 10 Nm
Secure front end harness to subframe

Note
2x stud clips
Connect front drive unit breather

Note
1x breather hose
Connect front drive unit harness connector

Note
1x connector, 1x harness clip, Engage locking tab
Connect harness to steering rack

Note
4x connector with locking tab
Connect powertrain return hose

Note
1x spring clip, 1x mounting clip
Install CFM

Note
Install from bottom, Assistance recommend Manipulate as required, Ensure harness is not pinched during install
Install fore crossmember

Note
2x bolts, 18mm, 90 Nm, Lift CFM away from beam to aid in clearance, Install beam by sliding rewards
Install lower CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Connect CFM connectors

Note
2x connectors, Engage locking tab
Install upper CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Secure harness to CFM

Note
1x grommet, 2x connector, 1x harness clip, Secure grommet then connect temperature sensor, Engage locking tab on louver connector
Connect radiator inlet coolant hose

Note
1x spring clips,Ensure hose is fully engaged with a push-pull-push test
Connect radiator to manifold hose to radiator

Note
1x spring clip, Ensure hose is fully engaged with a push-pull-push test
Install front lower fascia assembly

Note
Ensure no harnesses are pinched
Install RH fascia fastener and connectors

Note
1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Engage locking tab
Secure RH wheel liner

Note
4x clips
Install LH fascia fastener

Note
1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
Secure LH wheel liner

Note
4x clips
Install front fascia fasteners and covers

Note
2x covers, 6x bolts, 10mm, 4 Nm, Install tow hook covers
Install front center applique

Note
8x tabs, 1x connector, Ensure all tabs engage, Secure frunk release trigger connector
Install RH front wheel

Note
6x nuts, 21mm, 205 Nm
Install LH front wheel

Note
6x nuts, 21mm, 205 Nm
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque RH front wheel nuts

Note
6x nuts, 21mm, 205 Nm, Use star pattern
Install RH front wheel cap

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
Torque LH front wheel nuts

Note
6x nuts, 21mm, 205 Nm, Use star pattern
Install LH front wheel cap

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
Perform cooling system vacuum refill. See Cooling System (Vacuum Refill).
Reconnect MV power. See Disconnect MV Power (Modify).
Select 'Procedures'

Note
Lighting Bolt Icon > High Voltage > Procedures
Select 'Front Drive Inverter Replacement'

Note
Procedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
Select "Can redeploy," click "Run," and allow routine to complete

Note
Select 'Close' once complete
Run 'Coolant Air Purge' routine

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
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install coolant bottle cap
Run 'Thermal Performance' routine

Note
Via Front Drive Unit Replacement dashboard, Ensure result is 'Passed'
Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn

Note
Use safety stanchions to section off vehicle before driving vehicle on a lift
Select 'Front Drive Inverter Replacement'

Note
Procedures > 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

Note
Remove 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

Cybertruck Service Manual

Inverter - Front Drive Unit (Remove and Replace)

Figure 1

Figure 2

Figure 3