04/09/2024 13:12:11

Electromechanical Brake Booster - Brake Booster Assembly (Remove and Install)

Correction code 3320033011 FRT 1.68 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.

  • 2024-04-17: Added step and link to bleed the entire brake system manually before bleeding the brakes using Toolbox.
  • 2024-04-09: Cleaned up topic.
Warning IconA warning icon, calling your attention to a possibly risky situation
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. Open the LH front door and lower the LH front window.
  2. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  3. Remove all wheel assemblies. See Wheel Assembly (Remove and Install).
  4. Move the LH front seat fully rearward.
  5. Place the vehicle into Service Mode. See Service Mode.
  6. Open the powered frunk.
  7. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  8. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  9. Open the RH front door and lower the RH front window.
  10. Move the RH front seat fully rearward.
  11. Remove the LH and RH mid A-pillar trims. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
  12. Remove the LH and RH lower A-pillar trims. See A-B-C Positivet Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
  13. Remove the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
  14. Remove the LH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
  15. Remove the accelerator pedal side trim. See Passenger Compartment Carpet - Pedal - Side Trim (Remove and Install).
  16. Remove the accelerator pedal. See Accelerator Pedal (Remove and Install).
  17. Fold back the LH front cabin carpet.
  18. Lift up the LH carpet support foam from the rear edge, and then remove the foam from the vehicle.
  19. Remove the IP mid panel assembly. See Dash Panel - IP Mid Panel Assembly (Remove and Install).
  20. Disconnect MV power. See Disconnect MV Power.
  21. Remove the instrument panel lower assembly. See Dash Panel - Instrument Panel Lower Assembly (Remove and Install).
  22. Remove the nuts (x4) that attach the brake booster to the brake pedal assembly, then remove the cotter pin, then remove the clevis pin, and then remove the brake pedal from the vehicle.
    17 Nm (12.5 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  23. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
  24. Remove the bolts (x2) that attach the supermanifold to the megabeam.
    33 Nm (24.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Loosen the bolts, and then remove them by hand to avoid tool jamming.
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the supermanifold from underneath.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower the supermanifold until resting on the HVAC case.
  25. Remove the bolt, and then release the remote brake fluid reservoir.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket (magnetic)
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 datum
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift upwards to release the datum.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put the brake fluid reservoir aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid tipping over the brake fluid reservoir.
  26. Disconnect the A/C compressor logic electrical connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not push down on the red tab. Pull the tab to disengage the lock, and the pull it again to release the electrical connector.
  27. Release the connector lock, and then disconnect the A/C Compressor HV harness electrical connector from the A/C Compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the red locking tab away from the black lever, and then slide the black lever upwards.
  28. Remove the bolt that attaches the A/C compressor ground strap, and then release the harness edge clip once the ground strap is free.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket (magnetic)
  29. Remove the bolts (x3) that attach the A/C compressor to the megabeam.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the A/C compressor while removing the bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully remove the A/C compressor towards the front of the vehicle and under the megabeam.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put a fender cover on the fan housing and gently place the A/C compressor assembly down.
  30. Release the RH frunk harness clips (x2), and then disconnect the from windshield washer reservoir electrical connectors (x2).
  31. Remove the nut and the bolts (x2) that attach the windshield washer reservoir to the vehicle, and then disconnect the electrical connectors (x2), hose connections (x2), and hose clips (x2).
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Pinch the hose connector to release.
  32. Disconnect the coaxial electrical connector, and then release the clips (x2) that attach the RH frunk harness to the megabeam.
  33. Release the clips (x4) that attach the LH frunk harness to the megabeam, and then remove the stud.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E5
  34. Remove the MV battery. See MV BATTERY-LITHUM ION-48V (Remove and Install).
  35. Remove the bolts (x8) that attach the megabeam to the vehicle.
    165 Nm (121.7 lbs-ft)
    18 Nm (13.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • External Torx Plus EP14
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Loosen the bolts by hand first before using power tools.
  36. Remove the megabeam from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the electrical harness is not caught or pinched during the removal of the megabeam.
  37. Remove the brake cap, and then extract the brake fluid from the brake remote reservoir with a fluid extractor.
  38. Disconnect the brake booster electrical connectors (x3).
  39. Disconnect the brake booster plumbing quick release fitting (x1) and flare fittings (x2).
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 14 mm 6-point crowfoot flare nut
    Informational PurposesAn informational icon, calling your attention
    Note
    Place absorbent pads as required to catch brake fluid.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the remote reservoir hose by pushing the yellow tab inwards.
  40. Pull the brake booster straight outwards to release it from the vehicle.

Install

  1. Align the studs, and then push the brake booster flush against the bulkhead.
  2. Connect the brake booster plumbing quick release fitting (x1) and flare fittings (x2).
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 14 mm 6-point crowfoot flare nut
    Informational PurposesAn informational icon, calling your attention
    Note
    Place absorbent pads as required to catch brake fluid.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to ensure the hose is secured.
  3. Connect the brake booster electrical connectors (x3) and engage the locking tabs.
  4. Install the megabeam in the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the electrical harness is on the inboard side of the cowl mounting tabs, and the harness is not caught or pinched during the installation of the megabeam.
  5. Slide the MV battery rearwards into position, and then install the bolts (x2) that attach the MV battery to the vehicle.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  6. Install the bolts (x8) that attach the megabeam to the vehicle.
    165 Nm (121.7 lbs-ft)
    18 Nm (13.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • External Torx Plus EP14
  7. Install the stud, and then fasten the clips (x4) that attach the LH frunk harness to the megabeam.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E5
  8. Fasten the clips (x2) that attach the RH frunk harness to the megabeam, and then connect the coaxial electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to engage the coaxial electrical connector locking tab.
  9. Install the nut and the bolts (x2) that attach the windshield washer reservoir to the body, and then connect the hose connections (x2), connect the electrical connectors (x2), and the harness clips (x2).
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  10. Secure the RH frunk harness to the windshield washer reservoir clips (x2) and connect the electrical connectors (x2).
  11. Install the bolts (x2) that attach the supermanifold to the megabeam.
    33 Nm (24.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Start to fasten the bolts by hand.
  12. Install the bolts (x3) that attach the A/C compressor to the megabeam.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Start bolts by hand first, and then use power tools.
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the A/C compressor while installing the bolts.
  13. Align the datum and slide downwards to engage, and then install the bolt that attaches the remote brake fluid reservoir.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket (magnetic)
  14. Connect the A/C Compressor HV harness to the A/C Compressor, and then secure the connector lock.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the black lever down, and then push the red lock inwards.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the red locking tab is pushed all the way in. The red locking tab should sit flush with the black lever.
    Figure 1. Red locking tab is flush with black lever
    Figure 2. Red locking tab is not fully engaged
  15. Install the A/C compressor ground strap bolt.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket (magnetic)
  16. Connect the A/C compressor logic electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to engage the locking tab.
  17. Install the nuts (x4) that attach the brake booster to the brake pedal assembly, then install the clevis pin, and then secure the cotter pin.
    17 Nm (12.5 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  18. Install the instrument panel lower assembly. See Dash Panel - Instrument Panel Lower Assembly (Remove and Install).
  19. Install the IP mid panel assembly. See Dash Panel - IP Mid Panel Assembly (Remove and Install).
  20. Connect MV power. See Disconnect MV Power.
  21. Install the RH lower A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
  22. Install the RH mid A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
  23. Install the LH carpet support foam. Seat at the rear edge.
  24. Unfold the LH front cabin carpet into position.
  25. Install the accelerator pedal. See Accelerator Pedal (Remove and Install).
  26. Install the accelerator pedal side trim. See Passenger Compartment Carpet - Pedal - Side Trim (Remove and Install).
  27. Install the LH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
  28. Install the LH lower A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
  29. Install the LH mid A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
  30. Secure the LH side lower A-pillar primary seal.
  31. Install the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
  32. Restore the RH front seat back to its original position.
  33. Raise the RH front window and close the RH front door.
  34. Restore the LH front seat back to its original position.
  35. Bleed the entire brake system manually. See Brake Fluid Bleed - One Caliper.
  36. Bleed the entire brake system using Toolbox. See Brake Fluid Bleed - One Caliper.
  37. Exit Service Mode. See Service Mode.
  38. Install the frunk assembly. See Frunk Assembly (Remove and Install).
  39. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  40. Close the powered frunk.
  41. Install all wheel assemblies. See Wheel Assembly (Remove and Install).
  42. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  43. Raise the LH front window and close the LH front door.