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.
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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.

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Open the LH front door and lower the LH front window.
  3. Open the powered frunk.
  4. Place the vehicle into Service Mode. See Service Mode.
  5. Unlock the vehicle Gateway. See Gateway (Unlock).
  6. On the vehicle touchscreen, navigate to Service Mode PlusHigh VoltageProceduresFront Drive Inverter Replacement.
  7. Touch Store Boot + App Data and Start Fluid Fill/Drain, and then touch Run. Allow routine to complete.
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    Note
    Touch Close once completed.
  8. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  9. Disconnect MV power. See Disconnect MV Power (Modify).
  10. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  11. Remove the front fascia. See Front Bumper Fascia - Front Fascia (Remove and Install).
  12. Put a coolant catcher below the RH front of the vehicle.
  13. Disconnect radiator to manifold hose from radiator and plug connections
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    Note
    1x spring clip, Remove from vehicle, Plug hoses
  14. Disconnect manifold to radiator hose from radiator and plug connections
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    Note
    1x spring clips, Plug hoses
  15. Disconnect powertrain return hose from supermanifold
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    Note
    1x spring clip, Plug open fitting
  16. Disconnect powertrain return hose
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    Note
    1x spring clip, 1x mounting clip
  17. 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
  18. Remove upper CFM fasteners
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    Note
    2x bolts, 10mm, 10 Nm
  19. 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
  20. Loosen LH front wheel nuts
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    Note
    6x nuts, 21mm, 205 Nm
  21. 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
  22. Loosen RH front wheel nuts
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    Note
    6x nuts, 21mm, 205 Nm
  23. 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
  24. Remove front aero shield
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    Note
    11x bolts, 10mm, 6 Nm
  25. Remove mid aero shield
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    Note
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
  26. Remove all items from pockets and ensure not wearing metal items
  27. 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
  28. Put on HV insulating gloves and leather over gloves
  29. 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
  30. Remove leather over gloves and HV insulating gloves
  31. Remove bolt securing FDU HV harness to the FDU
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    Note
    1x bolt
  32. Disconnect FDU HV harness connector
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    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
  33. Release RH front wheel liner from HV battery chinstrap
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    Note
    1x push clip, 2x bolts, 10mm, 6 Nm
  34. Position coolant drain container underneath RH front of HV battery
  35. Disconnect powertrain supply and return hoses
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    Note
    2x spring clips, 2x clips, Plug hoses
  36. Disconnect CFM connectors
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    Note
    2x connectors, 2x clips
  37. Remove fore crossmember
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    Note
    2x bolts, 18mm, 90 Nm, Push up on CFM, Use hammer if needed, Recommend assistance
  38. Remove CFM
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    Note
    Recommend assistance, Remove from below impact beam, Ensure harness is not pinched during removal
  39. 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
  40. Disconnect front steering actuator
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    Note
    4x connectors, Release locking tabs
  41. Disconnect front drive unit breather
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    Note
    1x breather hose
  42. Release front end harness from subframe
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    Note
    2x stud clips
  43. Remove LH front wheel
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    Note
    6x nuts, 21mm, 205 Nm
  44. Remove LH front lower control arm shield
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    Note
    3x bolts, 10mm, 7 Nm
  45. Remove RH front wheel
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    Note
    6x nuts, 21mm, 205 Nm
  46. Remove RH front lower control arm aeroshield
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    Note
    3x bolts, 10mm, 7 Nm
  47. 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
  48. Move the subframe lifting tool underneath the front subframe area
  49. Connect air supply to subframe lifting tool
  50. Secure lifting tool onto front subframe
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    Note
    Recommend assistance, Secure subframe to subframe lifting tool with straps,
  51. 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
  52. Remove RH FDU mount bolt
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    Note
    1x bolt, E18, 85 Nm, Early production vehicles may have 16mm bolt
  53. Remove LH FDU mount bolt
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    Note
    1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
  54. 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
  55. Partially Lower subframe
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    Note
    Lower subframe to allow access to RH DI mount and bolts, support subframe with fixture, NVH cover removed for clarity
  56. Disconnect inverter to heat exchanger coolant hose
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    Note
    1x spring clip, Plug fittings, 1x mounting clip
  57. Remove PT return hose
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    Note
    1x cable tie, 1x spring clip, 2x edge clips, Cut cable tie and discard if present, Manipulate hose as required for removal, Plug open fitting
  58. Remove FDU supply hose
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    Note
    2x 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
  59. Remove NVH pad
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    Note
    7x clips, Revisions may be secured by velcro
  60. Remove RH FDU mount
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    Note
    3x bolts, E14, 35 Nm + 55 degrees,
  61. Remove label from phase cover
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    Note
    Discard label after removal
  62. Remove bolts securing phase out cover
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    Note
    2x bolts, EP10, 14 Nm
  63. 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
  64. 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
  65. Remove fasteners securing inverter to 3 phase lugs
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    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
  66. Put on ESD wrist strap and secure it to inverter housing
  67. Remove fasteners securing FDI
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    Note
    9x bolts, EP10, 12.5 Nm, Remaining bolts will be removed at a later step
  68. Remove FDI
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    Note
    Remove inverter through right side opening between subframe and body
  69. Remove inverter arc shield
    Informational PurposesAn informational icon, calling your attention
    Note
    If 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
  70. Place the drive inverter onto the ESD mat.
  71. Remove the ESD wrist strap from the old inverter.

Install

  1. Prepare the new inverter.
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    Note
    Save packaging to MRB the old inverter.
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    Note
    Remove any red protective covers.
  2. Secure the ESD strap onto the new inverter housing.
  3. Wipe the HV cable lugs to ensure contact surfaces are free of debris with an Isopropyl Alcohol (IPA) wipe.
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    Note
    Allow 1 minute dry time.
  4. For Tri Motor front drive inverter only: install new silicone 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
  5. Install FDI
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    Note
    Insert inverter through right side opening between subframe and body, Use caution to avoid damaging busbars,
  6. Install fasteners securing inverter to 3 phase lugs
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    Note
    9x bolts, EP10, 12.5 Nm, Fasteners can be reused
  7. 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
  8. Install phase out cover
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    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
  9. Install bolts securing phase out cover
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    Note
    2x bolts, EP10, 14 Nm, Fasteners can be reused
  10. Install new label to phase cover
  11. Remove the ESD wrist strap from the inverter.
  12. Take the old inverter and prepare for MRB. Label properly for return or disposal.
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    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.
  13. Install the leak test adapter plug to 12V connector at inverter - placeholder
  14. Install the leak test adapter to the HV connector - placeholder
  15. Connect regulator to adapter at the HV connector.
  16. Close both valves on the regulator test tool
  17. Connect regulator to air supply
  18. Open inlet valve on regulator valve
  19. Set regulator to 1 psi
  20. Open the outlet valve
  21. Wait 45 seconds for pressure to settle
  22. Close the inlet valve
  23. Record value of starting pressure
  24. Wait 60 seconds for test
  25. Record value of end pressure
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    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.
  26. Close both valves
  27. Disconnect air supply from regulator tool
  28. Disconnect regulator from leak test adapter at the HV connector.
  29. Remove leak test adapter from the HV connector.
  30. Remove the leak test adapter plug from 12V connector at inverter - placeholder
  31. Install RH DU mount
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    Note
    3x bolts, E14, 35 Nm + 55 degrees,
  32. Secure NVH cover
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    Note
    6x ball and socket clips
  33. Install PT return hose
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    Note
    1x 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
  34. Position FDU supply hose onto subframe
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    Note
    2x clips, Hose will be connected at a later step
  35. Connect inverter coolant inlet hose
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    Note
    1x spring clip, Remove plugs
  36. Connect inverter coolant return hose
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    Note
    1x spring clip, Remove plugs, One mounting clip
  37. Connect FDU logic connector
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    Note
    1x connector, Ensure no coolant or debris is present in connector housing at inverter or harness, Pivot locking arm up to secure
  38. Connect shop air supply to powertrain table
  39. Raise drive unit and subframe into position
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    Note
    Use caution to not damage components while raising subframe
  40. Install subframe bolts
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    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
  41. Install LH FDU mount bolt
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    Note
    1x bolt, E18, 85 Nm, Access through hole in HCU bracket, Early production vehicles may have 16mm bolt
  42. Install RH FDU mount bolt
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    Note
    1x bolt, E18, 85 Nm
  43. Remove subframe lifting tool from under vehicle
  44. Disconnect air supply from subframe lifting tool
  45. Secure FDU HV harness
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    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
  46. Connect powertrain supply and return hoses
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    Note
    2x spring clips, 2x clips, Remove plugs from hoses
  47. 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
  48. Install RH front lower control arm aeroshield
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 7 Nm
  49. Install RH front wheel
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    Note
    6x nuts, 21mm, 205 Nm
  50. Install LH lower control arm shield
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 7 Nm
  51. Install LH front wheel
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    Note
    6x nuts, 21mm, 205 Nm
  52. Secure front end harness to subframe
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    Note
    2x stud clips
  53. Connect front drive unit breather
    Informational PurposesAn informational icon, calling your attention
    Note
    1x breather hose
  54. Connect front drive unit harness connector
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    Note
    1x connector, 1x harness clip, Engage locking tab
  55. Connect harness to steering rack
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    Note
    4x connector with locking tab
  56. 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
  57. 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
  58. 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
  59. Connect CFM connectors
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    Note
    2x connectors, Engage locking tab
  60. Secure RH front wheel liner to HV battery chinstrap
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    Note
    1x push clip, 2x bolts, 10mm, 6 Nm
  61. Install the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
  62. Install the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
  63. Lower vehicle until tires are touching the ground
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  64. Torque RH front wheel nuts
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    Note
    6x nuts, 21mm, 205 Nm
  65. Install RH front wheel cap
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    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
  66. Torque LH front wheel nuts
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    Note
    6x nuts, 21mm, 205 Nm
  67. Install LH front wheel cap
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    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
  68. Install upper CFM fasteners
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    Note
    2x bolts, 10mm, 10 Nm
  69. Secure harness to CFM
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    Note
    1x grommet, 2x connector, 1x harness clip, Secure grommet then connect temperature sensor, Engage locking tab on louver connector
  70. Connect powertrain return hose
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    Note
    1x spring clip, 1x mounting clip
  71. Connect powertrain supply hose to supermanifold
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    Note
    1x spring clip, Plug hose
  72. 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
  73. Connect radiator to manifold hose to radiator
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    Note
    1x spring clip, Ensure hose is fully engaged with a push-pull-push test
  74. 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).
  75. Install vacuum refill cap onto coolant bottle assembly
  76. 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
  77. Fill container with at least 15L of coolant
  78. Place filled coolant container onto coolant drain & fill cart
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    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
  79. Setup coolant refill tool
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    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  80. Install vacuum refill hose to refill cap on coolant bottle
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    Note
    Perform push-pull-push test to verify hose is fully installed
  81. Position overflow hose into empty container
  82. Place refill hose inside filled coolant container
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    Note
    Make sure hose end is fully submerged into coolant
  83. Connect shop air supply to coolant refill tool
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    Note
    If not already done, Verify refill valve is set to off
  84. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
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    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  85. Slowly open the refill valve to allow coolant to be drawn into the system
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    Note
    Make sure hose end of refill hose is fully submerged during entire process
  86. Once the gauge reads zero, close the coolant refill valve
  87. Remove shop air supply to coolant refill tool
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    Note
    If not already done, Verify refill valve is set to off
  88. Remove coolant refill hose from coolant container
  89. Remove coolant overflow hose from coolant container
  90. Remove vacuum refill hose from refill cap on coolant bottle
  91. Remove vacuum refill cap from coolant bottle assembly
  92. Remove coolant refill tool from vehicle
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    Note
    Move coolant drain & fill cart away from vehicle
  93. Remove coolant container from inside underhood area
  94. Reconnect MV power. See Disconnect MV Power (Modify).
  95. Select 'Procedures'
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    Note
    Lighting Bolt Icon > High Voltage > Procedures
  96. Select 'Front Drive Inverter Replacement'
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    Note
    Procedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
  97. 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
  98. Select "Can redeploy," click "Run," and allow routine to complete
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    Note
    Select 'Close' once complete
  99. 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
  100. Inspect coolant level and top off as necessary
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    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required
  101. Install coolant bottle cap
  102. Run 'Thermal Performance' routine
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    Note
    Via Front Drive Unit Replacement dashboard, Ensure result is 'Passed'
  103. 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
  104. Raise vehicle partially and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set 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
  105. Select 'Procedures'
    Informational PurposesAn informational icon, calling your attention
    Note
    Lighting Bolt Icon > High Voltage > Procedures
  106. Select 'Front Drive Inverter Replacement'
    Informational PurposesAn informational icon, calling your attention
    Note
    Procedures > Drive-Inverter-Replacement > Front Drive Inverter Replacement
  107. Run ODIN routine PROC_DIF_X_RESOLVER-ERROR-LEARNvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Resolver Error Learn
  108. 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
  109. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
  110. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  111. Raise the LH front window and close the LH front door.
  112. Review wheel alignment requirements and add correction code as needed