23/07/2024 17:30:35

Front Subframe - Front Chassis Structure Assembly (Remove and Install)

Correction code 3001064012 3001064011 2.10 2.10 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.

Open LH front door

Note
Push LH B-pillar door trigger to release
Lower LH front window
Raise and support vehicle

Note
Set air suspension to "Jack Mode"
Place vehicle in service mode

Note
Via UI > Controls > Software, Touch and hold "Cybertruck" for 2 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
Unlock vehicle gateway

Note
After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information
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
Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' using the UI and PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT window will appear, Select 'Run'

Note
Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
Open powered front trunk

Note
Via exterior switch or UI
Remove rear underhood apron

Note
9x clips
Power down vehicle via UI

Note
Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release

Note
2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
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 lower valence fasteners

Note
2x clips, 2x covers, 6x bolts, 10mm, 6 Nm, Release covers to expose bolts
Remove front aero shield

Note
11x bolts, 10mm, 6 Nm
Disconnect CFM connectors

Note
2x connectors, 2x clips
Place coolant catcher below RH front of vehicle
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 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

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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
Remove lower CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Remove fore crossmember

Note
2x bolts, 18mm, 90 Nm, Push up on CFM, Use hammer if needed, Recommend assistance
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
Release harness from CFM

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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 CFM

Note
Recommend assistance, Remove from below impact beam, Ensure harness is not pinched during removal
Remove FDU gearcase mount bolts

Note
2x bolts, 18mm, 110 Nm, Shift drive unit rearward if tools become jammed once released
Remove LH front wheel

Note
6x nuts, 21mm, 205 Nm
Remove LH front lower control arm shield

Note
3x bolts, 10mm, 7 Nm
Remove LH front tie rod from LH front knuckle

Note
1x bolt, 21mm, 170 Nm
Remove bolts securing air spring module

Note
2x bolts, 21mm, 140 Nm, Be prepared for some spring load to release from bushings
Remove LH front end link from LH front lower arm

Note
1x bolt, 21mm, 175Nm, Counter hold stud, Discard nut after removal
Remove LH front lower arm from front knuckle

Note
1x nut, 24mm, 190 Nm, Discard after removal
Remove LH front lower arm from subframe

Note
2x bolts, 21mm, 175 Nm, 1x bolt, 24mm, 300 Nm, Discard after removal
Remove RH front wheel

Note
6x nuts, 21mm, 205 Nm
Remove RH front lower control arm shield

Note
3x bolts, 10mm, 7 Nm
Remove RH front tie rod from RH front knuckle

Note
1x bolt, 21mm, 170 Nm
Release RH damper from lower control arm

Note
2x bolts, 21mm, 140 Nm
Remove RH front end link from RH front lower arm

Note
1x bolt, 21mm, 175Nm, Counter hold stud, Discard nut after removal
Remove RH front lower arm from front knuckle

Note
1x nut, 24mm, 190 Nm, Discard after removal
Remove RH front lower arm from subframe

Note
2x bolts, 21mm, 175 Nm, 1x bolt, 24mm, 300 Nm, Discard after removal
Disconnect front steering actuator

Note
4x connectors, Release locking tabs
Remove stabilizer bar

Note
Manuver stabilizer bar to LH side wheel well, Then clear front subframe and dropdown to clear
Remove bolts securing front steering actuator to front subframe

Note
2x bolts, 21mm, 175 Nm, Bolt size may vary depending on build date
Remove front steering actuator assembly

Note
Using assistance, Maneuver assembly toward RH wheel well, Clear LH side tie rod end link and remove assembly from center of subframeBe cautious of actuator connector housing
Support front drive unit with strap

Note
Route strap around front drive unit gearcase mount, Secure to front casting, Ensure harnesses are not being pinched by strap, Tighten strap until drive unit lifts slightly off subframe
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,
Remove subframe bolts

Note
4x bolts, 24mm, 250 Nm, 2x bolts, 24mm, 220 Nm, 2x bolts, 21mm, 220 Nm, Recessed 24mm bolts have lower torque spec than rearmost 24mm bolts
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
Position subframe lifting tool with subframe assembly under vehicle
Connect shop air supply to powertrain table
Raise subframe into position

Note
Use caution to not damage components while raising subframe
Install subframe bolts

Note
4x bolts, 24mm, 250 Nm, 2x bolts, 24mm, 220 Nm, 2x bolts, 21mm, 220 Nm, Recessed 24mm bolts have lower torque spec than rearmost 24mm bolts
Remove subframe lifting tool from under vehicle
Disconnect air supply from subframe lifting tool
Remove strap from front drive unit

Note
Release ratcheting mechanism then feed strap out from under drive unit mount
Install drive unit gearcase mount bolts

Note
2x bolts, 18mm, 110 Nm
Position front steering actuator onto front subframe

Note
Using assistance, Maneuver assembly through front subframe into RH wheel well area, Clear LH front tie rod end link and position for installBe cautious of actuator connector housing
Install bolts securing front steering actuator to subframe

Note
2x bolts, 21mm, 175 Nm, Bolt size may vary depending on build date
Position stabilizer bar

Note
Recommend assistance, Maneuver through LH front wheel well, then maneuver through opposing wheel well and position
Connect front steering actuator

Note
4x connectors, Engage locking tabs
Install RH front lower arm to subframe

Note
2x bolts, 21mm, 175 Nm, 1x bolt, 24mm, 300 Nm, Install new bolts
Install RH front lower arm to RH front knuckle

Note
1x nut, 24mm, 190 Nm, Install new nut
Install LH front end link to LH front lower arm

Note
1x bolt, 21mm, 175Nm, Counter hold stud, Discard nut after removal
Secure RH damper to lower control arm

Note
2x bolts, 21mm, 140 Nm
Install RH tie rod to RH front knuckle

Note
1x bolt, 21mm, 170 Nm
Install RH front lower control arm shield

Note
3x bolts, 10mm, 7 Nm
Install RH front wheel

Note
6x nuts, 21mm, 205 Nm
Install LH front lower arm to subframe

Note
2x bolts, 21mm, 175 Nm, 1x bolt, 24mm, 300 Nm, Install new bolts
Install LH front lower arm to LH front knuckle

Note
1x nut, 24mm, 190 Nm, Install new nut
Install LH front end link to LH front lower arm

Note
1x bolt, 21mm, 175Nm, Counter hold stud, Discard nut after removal
Secure LH damper to lower control arm

Note
2x bolts, 21mm, 140 Nm
Install LH front tie rod to LH front knuckle

Note
1x bolt, 21mm, 170 Nm, Verify weight is evenly distributed to ease installation
Install LH front lower control arm shield

Note
3x bolts, 10mm, 7 Nm
Install LH front wheel

Note
6x nuts, 21mm, 205 Nm
Install CFM

Note
Install from bottom, Assistance recommend Manipulate as required, Ensure harness is not pinched during install
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 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
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
Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement

Note
2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection, If power cycling vehicle ensure at least 60 seconds has passed since powering down
Access thermal system routines using the UI

Note
Select quick controls > Service mode > Thermal > Actions
Select "Stop Thermal Fill Drain" through UI

Note
Allow routine to complete, ensure routine is successful
Select "Start Coolant Air Purge" using the UI

Note
Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
Raise vehicle fully

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

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
Install lower valence fasteners

Note
2x clips, 2x covers, 6x bolts, 10mm, 6 Nm, Secure covers
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
Perform Thermal Performance through the UI

Note
Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow https://toolbox.teslamotors.com/articles/206000
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 frunk assembly

Note
6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Install bolt covers to frunk floor, Install washer fluid cap, Install bumpstops by aligning tabs then turning clockwise, Ensure emergency frunk release functions
Install rear underhood apron

Note
9x clips, Adjust windshield seal as required
Close powered front trunk

Note
Via exterior switch or UI
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Exit Service Mode

Note
Via UI > Service > Exit, Press and hold "Exit Service Mode" button
Raise LH front window
Close LH front door