11/11/2024 13:29:34

Front Drive Unit Assembly and LH and RH Rear Drive Inverters (Tri-Motor) (Remove and Replace)

Correction code NEW 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.

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.

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.

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.
Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
Unlock the vehicle Gateway. See Gateway (Unlock).
Select 'Procedures'

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

Note
Procedures > Drive-Inverter-Replacement > Rear Left Drive Inverter ReplacementNote, If replacing the Right-Rear inverter then utilize the Right-Rear Inverter Dashboard instead
Select ‘Store Boot + App Data and Start Fluid Fill/Drain’, click ‘Run’, and allow routine to complete

Note
Select 'Close' once complete
Select 'Procedures'

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

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Procedures > Drive-Inverter-Replacement > Rear Right 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
Open the tonneau cover.
Open the tailgate.
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Disconnect MV power. See Disconnect MV Power.
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 frunk assembly

Note
6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Remove bolt covers from frunk floor, Remove washer fluid cap by gently prying upwards, Rotate bumpstops counter clockwise to release, the 25mm socket from PT Sensor kit can be used, Avoid straining emergency frunk release connector
Remove front center applique

Note
8x tabs, 1x connector, Release upper 4 tabs by pushing down then gently pull away, Release frunk release trigger connector
Remove front fascia fasteners

Note
2x covers, 4x bolts, 10mm, 4 Nm, Remove tow hook covers to expose bolts
Release clips securing front portion of the LH front wheel house liner

Note
4x clips
Remove front fascia LH side fastener

Note
1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
Release clips securing front portion of the RH front wheel house liner

Note
4x clips
Remove front fascia RH side fastener and connectors

Note
1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Pull red locking tab to release, Do not push down on locking tab
Remove front lower fascia assembly

Note
Place on suitable protective surface
Place coolant catcher below RH front of vehicle
Disconnect radiator to manifold hose from radiator

Note
1x spring clip, Remove from vehicle, Plug hoses
Disconnect manifold to radiator hose from radiator

Note
1x spring clips, Plug hoses
Disconnect powertrain return hose from supermanifold

Note
1x spring clip, Plug open fitting
Disconnect powertrain return hose

Note
1x spring clip, 1x mounting clip
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
Remove upper CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Remove LH front wheel cap

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
Loosen LH front wheel nuts

Note
6x nuts, 21mm, 205 Nm
Remove RH front wheel cap

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
Loosen RH front wheel nuts

Note
6x nuts, 21mm, 205 Nm
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove front aero shield

Note
11x bolts, 10mm, 6 Nm
Remove Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
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, 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
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 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
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 and return hoses

Note
2x spring clips, 2x clips, Plug hoses
Disconnect CFM connectors

Note
2x connectors, 2x clips
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
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
Disconnect front steering actuator

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

Note
1x connector, 1x harness clip, Release locking tab
Disconnect front drive unit breather

Note
1x breather hose
Release front end harness from subframe

Note
2x stud clips
Remove LH front wheel

Note
6x nuts, 21mm, 205 Nm
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
Remove LH front brake rotor
Release LH chassis jumper harness from knuckle

Note
3x connectors, 3x harness clips, 1x grommet, Release locking tabs
Remove LH front lower control arm shield

Note
3x bolts, 10mm, 7 Nm
Release LH front damper from lower control arm

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

Note
1x nut, 18mm, 85 Nm, Use step ladder as needed
Remove RH front wheel

Note
6x nuts, 21mm, 205 Nm
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
Remove RH front brake rotor
Release RH chassis jumper harness from knuckle

Note
3x connectors, 3x harness clips, 1x grommet, Release locking tabs
Remove RH rear lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
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
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Move the subframe lifting tool underneath the front subframe area
Connect air supply to subframe lifting tool
Placeholder - Position and support the front subframe with subframe lifting tool

Note
Recommend assistance, Secure subframe to subframe lifting tool with straps,
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 RH FDU mount bolt

Note
1x bolt, E18, 85 Nm
Remove LH FDU mount bolt

Note
1x bolt, E18, 85 Nm, Access through hole in HCU bracket
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
Secure drive unit sling to gantry
Attach drive unit sling tool to drive unit

Note
3x hooks
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
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
Install RH FDU mount bolt

Note
1x bolt, E18, 85 Nm
Remove subframe lifting tool from under vehicle
Disconnect air supply from subframe lifting tool
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
3x connectors, 3x harness clips, 1x grommet, Engage locking tabs
Install RH front brake rotor

Note
Rotor will be loose until caliper is installed
Install RH front caliper

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

Note
1x bolt, 10mm, 10 Nm
Install RH front wheel

Note
6x nuts, 21mm, 205 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
3x connectors, 3x harness clips, 1x grommet, Engage locking tabs
Install LH front brake rotor

Note
Rotor will be loose until caliper is installed
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
Install LH front wheel

Note
6x nuts, 21mm, 205 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
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
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
Connect CFM connectors

Note
2x connectors, Engage locking tab
Connect powertrain supply and return hoses

Note
2x spring clips, 2x clips, Remove plugs from hoses
Secure RH front wheel liner to HV battery chinstrap

Note
1x push clip, 2x bolts, 10mm, 6 Nm
Install FDU HV harness

Note
1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
Install front aero shield

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
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
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
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
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 powertrain return hose

Note
1x spring clip, 1x mounting clip
Connect powertrain supply hose from supermanifold

Note
1x spring clip, Plug hose
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, 4x 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
Open bed cargo tub lid
Remove cargo tub struts from cargo lid

Note
2x strut clips
Remove bed cargo tub lid

Note
4x bolts, 10mm, 5 Nm, Recommend assistance
Remove fastener covers from bed floor assembly

Note
6x covers
Remove bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
Remove LH bed closeout panel

Note
6x clips, 1x tab, Release LH tailgate cable by disengaging lock spring from bolt and sliding cable eyelet off to allow removal of bed closeout panel from vehicle
Remove LH upper bed side wall assembly

Note
8x clips, Start from rear, Lift tonneau seal as required. Pull from the bottom downwards.
Remove LH lower bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, T45, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Release locking tabs, Disconnect bed outlet connectors from bed side wall and ground strap, 1x bolt, 10mm, 10 Nm, 2x connectors, Release locking tabs, Slide lock to release, Recommend assistance
Remove RH bed closeout panel

Note
6x clips, 1x tab, Release RH tailgate cable by disengaging lock spring from bolt and sliding cable eyelet off in order to remove bed closeout panel from vehicle
Remove RH upper bed side wall assembly

Note
8x clips, 1x connector. Pull downwards
Remove RH bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, T40, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Release locking tabs
Remove bolts securing bed cargo tub

Note
2x bolts, 10mm, 8 Nm
Remove bed cargo tub from vehicle

Note
Recommend assistance
Position coolant catcher below rear drive unit
Release LH RDU inverter to heat exchange hose from drive inverter

Note
1x clip, 1x hose, Plug both ends, Use a flathead to release clip on hose and release hose, Move aside as needed, Use a shop towel to clean and remove remaining coolant residue from driver inverter
Release RDU supply hose from drive unit

Note
2x clip, 2x hose, Plug both ends, Use a flathead to release clip on hose and release hose, Move aside as needed, Use a shop towel to clean and remove remaining coolant residue from driver inverter
Remove bolt securing LH RDU HV harness onto RDU

Note
1x bolts, 10mm, 11 Nm
Disconnect LH RDU HV cable from RDU

Note
1x connector, Disengage locking tab then release connector body, Move aside as needed
Disconnect LH RDU logic connection

Note
1x harness clip, 1x connector, Release locking tab, Do not get coolant ingress into this connector, Move aside as needed
Remove phase access cover label

Note
Label is one time use, Discard after removal
Remove bolts securing phase out cover assembly

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

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 bolts securing 3 phase busbars to rear inverter assembly

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 bolts securing LH RDU inverter to gearbox assembly

Note
9x bolts, EP10, 12.5 Nm
Remove LH drive inverter from RDU and drain coolant

Note
Take caution to avoid damage to PCBA
Place drive inverter onto ESD mat
Remove ESD wrist strap from old inverter
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 fasteners securing inverter to gearbox assembly

Note
9x bolts, EP10, Install hand tight, Torque at a later step
Torque fasteners securing inverter to gearbox assembly

Note
9x bolts, EP10, 12.5 Nm, Torque two fasteners nearest alignment dowels first
Install bolts securing LH drive 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
Install phase out cover assembly

Note
If phase out cover or O-rings are damaged then replace with a new unit
Install bolts securing RDU phase out cover assembly

Note
2x bolts, EP10, 14 Nm
Install phase out cover label

Note
One time use, install new label
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
Remove bolt securing RH RDU HV harness onto RDU

Note
1x bolts, 10mm, 11 Nm
Disconnect RH RDU HV cable from RDU

Note
1x connector, Disengage locking tab then release connector body, Move aside as needed
Disconnect RH RDU logic connection

Note
1x harness clip, 1x connector, Release locking tab, Do not get coolant ingress into this connector, Move aside as needed
Remove phase access cover label

Note
Label is one time use, Discard after removal
Remove bolts securing phase out cover assembly

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

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 bolts securing 3 phase busbars to rear inverter assembly

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 bolts securing RH RDU inverter to gearbox assembly

Note
9x bolts, EP10, 12.5 Nm
Remove RH drive inverter from RDU and drain coolant

Note
Take caution to avoid damage to PCBA
Place drive inverter onto ESD mat
Remove ESD wrist strap from old inverter
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 fasteners securing inverter to gearbox assembly

Note
9x bolts, EP10, Install hand tight, Torque at a later step
Torque fasteners securing inverter to gearbox assembly

Note
9x bolts, EP10, 12.5 Nm, Torque two fasteners nearest alignment dowels first
Install bolts securing LH drive 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
Install phase out cover assembly

Note
If phase out cover or O-rings are damaged then replace with a new unit
Install bolts securing RDU phase out cover assembly

Note
2x bolts, EP10, 14 Nm
Install phase out cover label

Note
One time use, install new label
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
Connect RH RDU logic connection

Note
1x connector, verify lever is fully engaged, 1x harness clip, Inspect for any fluid in connector and clean before installation
Connect RH RDU HV connector

Note
1x connector, Engage locking tab
Install bolt securing RH RDU HV harness onto RDU

Note
1x bolt, 10mm, 11 Nm
Connect LH RDU logic connection

Note
1x connector, verify lever is fully engaged, 1x harness clip, Inspect for any fluid in connector and clean before installation
Connect LH RDU HV connector

Note
1x connector, Engage locking tab
Install bolt securing LH RDU HV harness onto RDU

Note
1x bolt, 10mm, 11 Nm
Secure RDU supply hose onto drive inverters

Note
2x clip, 2x hose, Re-secure clip if it detached from hose, Engage hose and verify the hose is fully and properly secured, Perform push-pull-push test
Secure LH RDU inverter to heat exchange hose from drive inverter

Note
1x clip, 1x hose, Re-secure clip if it detached from hose, Engage hose and verify the hose is fully and properly secured, Perform push-pull-push test
Secure RH RDU inverter to heat exchange hose from drive inverter

Note
1x clip, 1x hose, Re-secure clip if it detached from hose, Engage hose and verify the hose is fully and properly secured, Perform push-pull-push test
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove coolant catcher from below vehicle
Install Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 onto mid aeroshield bolts and install fasteners
Remove coolant bottle cap
Install vacuum refill cap onto coolant bottle assembly
Place empty coolant container into front storage area

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
Fill container with at least 15L of coolant
Place filled coolant container onto coolant drain & fill cart

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
Setup coolant refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose to refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully installed
Position overflow hose into empty container
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Slowly open the refill valve to allow coolant to be drawn into the system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once the gauge reads zero, close the coolant refill valve
Remove shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove vacuum refill cap from coolant bottle assembly
Remove coolant refill tool from vehicle

Note
Move coolant drain & fill cart away from vehicle
Remove coolant container from inside underhood area
Reconnect MV power. See Disconnect MV Power.
Access front drive unit replacement panel via Service Mode Plus UI

Note
Controls > Service Mode > High Voltage > Procedures > Front Drive Unit Replacement
Run 'Stop Coolant Fill/Drain' routine

Note
Via Front Drive Unit Replacement dashboard, Ensure result is 'Passed'
Run 'Write Drive Type' routine

Note
Via Front Drive Unit Replacement dashboard, Ensure result is 'Passed'
Select 'Procedures'

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

Note
Procedures > Drive-Inverter-Replacement > Rear Right Drive Inverter Replacement
Select "Restore Bootloader Data", click "Run", and allow routine to complete

Note
Select 'Close' once complete, Bootloader data restore must be completed before a CAN redeploy is performed
Select 'Procedures'

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

Note
Procedures > Drive-Inverter-Replacement > Rear Left Drive Inverter ReplacementNote, If replacing the Right-Rear inverter then utilize the Right-Rear Inverter Dashboard instead
Select "Restore Bootloader Data", click "Run", and allow routine to complete

Note
Select 'Close' once complete, Bootloader data restore must be completed before a CAN redeploy is performed
Run 'CAN Redeploy' routine

Note
CAN redeploy will start immediately
Select 'Procedures'

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

Note
Procedures > Drive-Inverter-Replacement > Rear Right Drive Inverter Replacement
Select "Restore Application Data", click "Run", and allow routine to complete

Note
Select 'Close' once complete
Select 'Procedures'

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

Note
Procedures > Drive-Inverter-Replacement > Rear Left Drive Inverter ReplacementNote, If replacing the Right-Rear inverter then utilize the Right-Rear Inverter Dashboard instead
Select "Restore Application Data", click "Run", and allow routine to complete

Note
Select 'Close' once complete
Select ‘Coolant Air Purge’, click ‘Run’, and allow routine to complete

Note
Select 'Close' once complete
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
Access front drive unit replacement panel via Service Mode Plus UI

Note
Controls > Service Mode > High Voltage > Procedures > Front Drive Unit Replacement
Run 'Thermal Performance' routine

Note
Via Front Drive Unit Replacement dashboard, Ensure result is 'Passed'
Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
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
Raise vehicle partially and lower lift onto locks

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
Select 'Procedures'

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

Note
Procedures > Drive-Inverter-Replacement > Rear Right Drive Inverter Replacement
Run ODIN routine PROC_DIR_X_RESOLVER-ERROR-LEARN
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
Remove safety stanchions from around vehicle after resolver learn is completed

Note
Remove all stanchions after vehicle is finished with the resolver error learn
Install bed cargo tub into vehicle

Note
Recommend assistance
Install bolts securing bed cargo tub

Note
2x bolts, 10mm, 8 Nm, Align tub as needed
Install RH bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, T40, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Recommend assistance
Install RH bed closeout panel

Note
6x clips, 1x tab, Release RH tailgate cable to install bed closeout panel from vehicle
Install RH upper bed side wall assembly

Note
8x clips, Replace any missing or damaged clips, Lift tonneau seal as required
Install LH lower bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, 13mm, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Secure locking tabs, Connect bed outlet connectors onto bed side wall and ground strap, 1x bolt, 10mm, 10 Nm, 2x connectors, Secure locking tabs, Slide lock to secure, Recommend assistance
Install LH bed closeout panel

Note
6x clips, 1x tab, Secure LH tailgate cable once closeout installed
Install LH upper bed side wall assembly

Note
8x clips, Replace any missing or damaged clips, Lift tonneau seal as required
Install bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
Install fastener covers onto bed floor assembly

Note
6x covers
Install bed cargo tub lid

Note
4x bolts, 10mm, 6 Nm, Snug bolts, Torque will be done at later step, Position bed cargo tub lid onto vehicle, Install bolts securing bed cargo tub lid onto hinges, Recommend assistance
Install cargo tub struts onto cargo lid

Note
2x strut clips
Close bed cargo tub lid
Close the tonneau cover.
Close the tailgate.
Run ODIN routine PROC_ICE_X_EXIT-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

Front Drive Unit Assembly and LH and RH Rear Drive Inverters (Tri-Motor) (Remove and Replace)

Figure 1

Figure 2

Figure 3