16/10/2024 12:41:02

Front Drive Unit Assembly - Front Drive Unit (Remove and Install)

Correction code 3901049111 FRT 2.46 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.

  • 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.
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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.
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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.

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. On the vehicle touchscreen, navigate to quick controls > Service mode > Diagnostics > Thermal to access the thermal system routines.
    Informational PurposesAn informational icon, calling your attention
    Note
    Authorize routines by holding right turn signal, pressing brake pedal for 10 seconds with key on the phone dock.
  6. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify indicator displays green for Coolant readiness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Thermal Fill Drain routine has a 50 minute time limit.
  7. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  8. Disconnect MV power. See Disconnect MV Power.
  9. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  10. Remove the front center applique. See Front Grille and Applique - Front Center Applique Assembly (Remove and Install).
  11. Remove the front fascia. See Front Bumper Fascia - Front Fascia (Remove and Install).
  12. Position a coolant catcher below the RH front of the vehicle.
  13. Release the spring clip, disconnect the radiator outlet hose from the radiator, and then plug the fittings.
  14. Release the spring clip, disconnect the radiator inlet hose from the radiator, and the plug the fittings.
  15. Release the spring clip, disconnect the powertrain supply hose from the Supermanifold, and then plug the fittings.
  16. Release the spring clip, disconnect the powertrain return hose, and then release the mounting clip and plug the fittings.
  17. Release the temperature sensor from the CFM, and then disconnect the electrical connector.
  18. Release the connector lock, and then disconnect the louver electrical connector.
  19. Release the harness clips (x5) and grommet that attach the harness to the CFM, and then pull the harness through from the frunk area.
  20. Remove the lower bolts (x2) that attach the CFM to the vehicle.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Figure 1. LH shown; RH similar
  21. Remove the LH and RH front wheel caps. See Wheel Cover - Front - LH (Remove and Install).
  22. Remove the LH and RH front wheels. See Wheel Assembly (Remove and Install).
  23. Remove the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
  24. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
  25. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
  26. Disconnect the front drive unit HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab, and then rotate the release lever up to disengage the connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the release lever up.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the alignment tabs on the FDU header are not damaged.
  27. Remove the bolts (x2) and release the clip that attach the RH front wheel liner to the HV battery chinstrap.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  28. Position the coolant drain container underneath the RH front of the HV battery.
  29. Disconnect the powertrain supply and return hoses.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 spring clips, x2 clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug the hoses.
  30. Disconnect the Cooling Fan Module (CFM) electrical connectors (x2).
    Figure 2. LH shown; RH similar
  31. With assistance, remove the bolts (x2) that attach the fore crossmember to the front subframe, and then remove the crossmember from the vehicle.
    90 Nm (66.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Push up on the CFM to aid in releasing the crossmember. Use a hammer, if needed.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    Figure 3. LH shown; RH similar
  32. Remove the upper bolts (x4) that attach the CFM to the vehicle.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The upper fasteners are accessible from the frunk area.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  33. With assistance, remove the CFM through the bottom of the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the electrical harness is not pinched during removal.
  34. Partially lower the vehicle.
  35. Disconnect the steering rack electrical connectors (x4).
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tabs.
  36. Disconnect the front drive unit harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab.
  37. Disconnect the front drive unit breather.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 breather hose
  38. Release the front end harness from the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 stud clips
  39. Remove the bolt that attaches the LH front brake hose bracket to the knuckle. Repeat this step for the RH front brake hose bracket.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
  40. Remove the bolts (x2) that attach the LH front caliper to the knuckle, and then set the caliper aside with an S-hook. Repeat this step for the RH front caliper.
    315 Nm (232.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    The rotor will be loose until the caliper is installed.
  41. Remove the LH front brake rotor from the hub. Repeat this step for the RH front brake rotor.
  42. Disconnect the LH chassis jumper harness from the knuckle. Repeat this step for the RH chassis jumper harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 connectors, x3 harness clips, x1 grommet
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tabs.
  43. Remove the bolts (x3) that attach the LH lower control arm shield. 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
  44. Remove the bolts (x2) that attach the LH damper to the lower control arm. Repeat this step for the RH damper.
    135 Nm (99.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  45. Remove the nut that attaches the LH front upper control arm to the knuckle. Repeat this step for the RH side of the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a step ladder as needed.
  46. Fully raise the vehicle.
  47. Move the subframe lifting tool underneath the front subframe area.
  48. Connect air supply to the subframe lifting tool.
  49. Placeholder - Position and support the front subframe with the subframe lifting tool.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the front subframe to subframe lifting tool with straps.
  50. Position the rear FDU support posts to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Both FDU supports need to engage the front drive unit. The left side post is dimpled and fits into a recess on the front drive unit, and the right side post has a Teflon block that sits against the front drive unit. Both posts are threaded and the handle should be turned until the posts are tight.
  51. Remove the bolt that attach the ground strap to the HV battery chinstrap.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  52. Remove the bolt that attaches the RH FDU mount.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
  53. Remove the bolt that attaches the LH FDU mount.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
    Informational PurposesAn informational icon, calling your attention
    Note
    Access through the hole in the HCU bracket.
  54. Remove the front 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. Lower the front subframe from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Watch for any missed connections or trapped harnesses when lowering the front subframe.
  56. Disconnect the air supply from the subframe lifting tool.
  57. Remove the subframe lifting tool from under the vehicle.
  58. Remove the powertrain supply hose from the front drive unit and the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip, x2 clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Release from lower inverter port, and then set it aside.
  59. Remove the powertrain return hose from the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip
    Informational PurposesAn informational icon, calling your attention
    Note
    Release from the heat exchanger, and then set it aside.
  60. Remove the front drive unit harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    x4 connectors, x10 harness clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Release locking tabs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release inverter connector lock, and then pivot lever out to release.
  61. Release halfshafts from the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the front drive unit as required to allow halfshafts to clear the front drive unit.
  62. Remove the bolts (x2) that attach the front drive unit gearcase mount.
    110 Nm (81.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the front drive unit rearward if tools become jammed once released.
  63. Position the drive unit stand underneath the gantry.
  64. Attach the drive unit sling tool to the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 hooks
  65. Secure the drive unit sling to the gantry.
  66. Raise the sling to lift the drive unit out of the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the drive unit rearwards to clear the steering gear.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate as required to clear the halfshafts.
  67. Position the empty drive unit crate below the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to adjust sling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the pallet if no empty crate is available.
  68. Lower the drive unit into the drive unit crate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the pallet if no empty crate is available.
  69. Remove the lifting sling from the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 hooks
  70. Attach the drive unit sling tool to the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 hooks
  71. Secure the drive unit sling to the gantry.

Install

  1. Raise the front drive unit out of the drive unit crate.
  2. Lower sling to position the front drive unit into the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the front drive unit to clear the steering gear.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate as required to clear the halfshafts.
  3. Position the rear FDU support posts to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Both FDU supports need to engage the front drive unit. The left side post is dimpled and fits into a recess on the front drive unit, and the right side post has a Teflon block that sits against the front drive unit. Both posts are threaded and the handle should be turned until the posts are tight.
  4. Remove the lifting sling from the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 hooks
  5. Install the bolts (x2) that attach the front drive unit gearcase mount.
    110 Nm (81.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the front drive unit as required to align.
  6. Install the halfshafts to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the front drive unit as required to allow halfshafts to clear the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that an audible click is heard as the circlip engages.
  7. Install the front drive unit harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    x4 connectors, x10 harness clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage the locking tabs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pivot inverter connector lever to engage.
  8. Install the powertrain return hose to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip
  9. Install the powertrain supply hose to the front drive unit and the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip, x2 clips
  10. Position the subframe lifting tool and front subframe under the vehicle.
  11. Connect shop air supply to the powertrain table.
  12. Raise the drive unit and front subframe into position.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage components while raising the front subframe.
  13. Install the front 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
  14. Install the LH FDU mount bolt.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
    Informational PurposesAn informational icon, calling your attention
    Note
    Access through the hole in the HCU bracket.
  15. Install the RH FDU mount bolt.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
  16. Install the bolt that attach the ground strap to the HV battery chinstrap.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  17. Remove the subframe lifting tool from under the vehicle.
  18. Disconnect the air supply from the subframe lifting tool.
  19. Partially lower the vehicle.
  20. Install the nut that attaches the RH front upper control arm to the knuckle. Repeat this step for the LH side of the vehicle.
    80 Nm (59.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a step stool as needed.
  21. Install the bolts (x2) that attach the RH damper to the lower control arm. Repeat this step for the LH damper.
    135 Nm (99.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  22. Remove the bolts (x3) that attach the RH lower control arm shield. Repeat this step for the LH lower control arm shield.
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  23. Secure the RH chassis jumper harness to the knuckle. Repeat this step for the LH chassis jumper harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 connectors, x3 harness clips, x1 grommet
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage the locking tabs.
  24. Install the RH front brake rotor. Repeat this step for the LH front brake rotor.
    Informational PurposesAn informational icon, calling your attention
    Note
    The rotor will be loose until the caliper is installed.
  25. Install the bolts (x2) that attach the RH front caliper to the knuckle. Repeat this step for the LH front caliper.
    315 Nm (232.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  26. Install the bolt that attaches the RH front brake hose bracket to the knuckle. Repeat this step for the LH front brake hose bracket.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
  27. Position the RH front wheel onto the vehicle, and then install and hand tighten the lug nuts. Repeat this step for the LH front wheel.
  28. Secure the front end harness to the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 stud clips
  29. Connect the front drive unit breather.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 breather hose
  30. Connect the front drive unit harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage locking tab.
  31. Connect steering rack electrical connectors (x4).
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage locking tabs.
  32. Raise the vehicle fully.
  33. With assistance, position the CFM into the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the CFM from the bottom of the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the electrical harness is not pinched during installation.
  34. Position the fore crossmember into the vehicle, and then install the bolts (x2) that attach the fore crossmember to the front subframe.
    90 Nm (66.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift the CFM away from the beam to aid in clearance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the beam by sliding it rewards.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    Figure 4. LH shown; RH similar
  35. Connect the CFM electrical connectors (x2), and then engage the connector locks.
    Figure 5. LH shown; RH similar
  36. Install the upper bolts (x4) that attach the CFM to the vehicle.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The upper fasteners are accessible from the frunk area.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  37. Connect powertrain supply and return hoses.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clips, 2x clips, Remove plugs from hoses
  38. Install the bolts (x2) and fasten the clip that attach the RH front wheel liner to the HV battery chinstrap.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  39. Install the front drive unit HV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 bolt, 10 mm, 10 Nm
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab engages.
  40. Install the mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    x6 clips; x3 bolts, 15 mm, 70 Nm; x3 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 Nm
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply Loctite 222 onto mid aero shield bolts and install fasteners.
  41. Install the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
  42. Install the LH and RH front wheels. See Wheel Assembly (Remove and Install).
  43. Install the lower bolts (x2) that attach the CFM to the vehicle.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Figure 6. LH shown; RH similar
  44. Feed the electrical harness through the frunk area, and then secure the harness clips (x5) and grommet that attach the harness to the CFM.
  45. Connect the louver electrical connector, and then engage the connector lock.
  46. Connect the temperature sensor electrical connector, and then secure the connector to the vehicle.
  47. Connect powertrain return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x mounting clip
  48. Connect powertrain supply hose from supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose
  49. Connect the radiator inlet hose to the radiator, and then secure the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to ensure the hose is fully engaged.
  50. Connect the radiator outlet hose to the radiator, and then secure the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to ensure the hose is fully engaged.
  51. Install the front fascia. See Front Bumper Fascia - Front Fascia (Remove and Install).
  52. Install the front center applique. See Front Grille and Applique - Front Center Applique Assembly (Remove and Install).
  53. Refill the cooling system. See Cooling System (Vacuum Refill).
  54. Reconnect MV power. See Disconnect MV Power.
  55. Exit Service Mode. See Service Mode.
  56. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  57. Raise the LH front window and close the LH front door.
  58. Review wheel alignment requirements and add correction code as needed.