2025-08-13

Drive Unit - Front (Remove and Install)

Correction code 3901049111 FRT 3.36 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

2025-08-13: Updated entire procedure to latest validation.
2024-10-16: Updated torque values for subframe fasteners.
2024-03-28: Added missing steps for remove/install upper control arm to knuckle and disconnect/connect coolant hoses.

Warning

Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.

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.

Procedure

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.
Access thermal system routines using the UI

Note
Select quick controls > Service mode > Diagnostics > Thermal, Authorize routines by holding right turn signal, depressing brake pedal for 10 seconds with key on phone dock
Touch Coolant System to enter coolant circuit screen. Touch Coolant Fill/Drain and then "PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT' window appears. Touch Run.

Note
Verify indicator displays green for Coolant readiness.

Note
Thermal Fill Drain routine has a 50 minute time limit.
Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
Disconnect MV power. See Disconnect MV Power (Modify).
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
Remove mid aero shield. See Skid Plate - Rear (Remove and Install).
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003
Put on HV insulating gloves and leather over gloves
Verify no HV - Install amp clamp to RDU HV harness

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
Remove leather over gloves and HV insulating gloves
Remove the front aero shield. See Aeroshield - Front (Remove and Install).
Remove front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Remove the bolts (x3) that attach the LH lower control arm shield, and then remove the shield from the vehicle. Repeat this step for the RH lower control arm shield.
7 Nm (5.2 lbs-ft)
TIp
Use of the following tool(s) is recommended:

10 mm socket
Figure 1. LH shown; RH similar
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 wheels. See Wheel Assembly (Remove and Install).
Remove the frunk assembly. See Frunk Assembly (Remove and Install).
Remove the front center applique. See Front Center Applique Assembly (Remove and Install).
Remove the front fascia. See Front Fascia (Remove and Install).
Remove the cooling fan module. See Module - Cooling Fan (Remove and Install).
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 the steering rack electrical connectors (x4).

Note
Release the locking tabs.
Disconnect the front drive unit breather.

Note
x1 breather hose
Disconnect the front drive unit harness connector.

Note
x1 harness clip

Note
Release the locking tab.
Release the front end harness from the front subframe.

Note
x2 stud clips
Remove the bolt that attaches the LH front brake hose bracket to the knuckle.
10 Nm (7.4 lbs-ft)
TIp
Use of the following tool(s) is recommended:

10 mm deep socket
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
Remove powertrain supply hose from FDU and front subframe

Note
1x spring clip, 2x clips, Release from lower inverter port and set aside
Remove powertrain return hose from FDU

Note
1x spring clip, Release from heat exchanger and set aside
Remove front drive unit harness

Note
4x connectors, 10x harness clips, Release locking tabs, Release inverter connector lock then pivot lever out to release
Release halfshafts from front drive unit

Note
Shift drive unit as required to allow shafts to clear drive unit
Remove FDU gearcase mount bolts

Note
2x bolts, 18mm, 110 Nm, Shift drive unit rearward if tools become jammed once released
Position drive unit stand underneath gantry
Attach drive unit sling tool to drive unit

Note
3x hooks
Secure drive unit sling to gantry
Raise sling to lift drive unit out of subframe

Note
Recommend assistance, Pull drive unit rearwards to clear steering gear, Rotate as required to clear halfshafts
Position empty drive unit crate below drive unit

Note
May need to adjust sling, Use pallet if no empty crate available
Lower drive unit onto empty drive unit crate

Note
Use pallet if no empty crate available
Remove lifting sling from drive unit

Note
3x hooks
Attach drive unit sling tool to drive unit

Note
3x hooks
Secure drive unit sling to gantry
Raise drive unit out of drive unit crate
Lower sling to position drive unit into subframe

Note
Recommend assistance, Position drive unit to clear steering gear, Rotate as required to clear halfshafts
Position the rear FDU support posts to the 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 lifting sling from drive unit

Note
3x hooks
Install RDU gearcase mount bolts

Note
2x bolts, 18mm, 110 Nm, Shift drive unit as required to align
Install halfshafts to front drive unit

Note
Shift drive unit as required to allow shafts to clear drive unit, Verify an audible click is heard as the circlip engages
Install front drive unit harness

Note
4x connectors, 10x harness clips, Engage locking tabs, Pivot inverter connector lever to engage
Install powertrain return hose to FDU

Note
1x spring clip
Install powertrain supply hose to FDU and front subframe

Note
1x spring clip, 2x clips
Position subframe lifting tool with subframe assembly under vehicle
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 the mid aero shield. See Skid Plate - Rear (Remove and Install).
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
Install nut securing LH front upper control arm to knuckle

Note
1x nut, 18mm, 85 Nm, Use step stool as needed, Install new nut
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 the front fascia. See Front Fascia (Remove and Install).
Install the LH and RH front wheels. See Wheel Assembly (Remove and Install).
Refill the cooling system. See Cooling System (Vacuum Refill).
Install frunk assembly. See Frunk Assembly (Remove and Install).
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
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

Drive Unit - Front (Remove and Install)

Procedure

Figure 1

Figure 2

Figure 3