23/07/2024 17:33:16

Rear Drive Unit (Dual Motor) (Remove and Install)

Correction code 4001093071 4001093072 FRT 3.18 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 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 powered frunk.
  2. Open the LH front door and lower the LH front window.
  3. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  4. On the vehicle touchscreen, navigate to Service mode > Diagnostics > Thermal to access the thermal system routines.
    Informational PurposesAn informational icon, calling your attention
    Note
    Authorize routines by holding the right turn signal, and then depressing the brake pedal for 10 seconds with key on phone dock.
  5. Tap Coolant System to enter the coolant circuit screen, tap Coolant Fill/Drain, and then tap Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    Run routine PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
    .
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the indicator displays green for Coolant readiness. Thermal Fill Drain routine has a 50 minute time limit.
  6. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  7. In Toolbox, click the Actions tab, and then search for "EPB".
  8. Click PROC_EPB_X_SERVICE-MODEvia Toolbox: (link)via Service Mode:
    • Chassis ➜ Brakes ➜ EPB Service Mode
    • Chassis ➜ Brakes ➜ EPB Service Mode
    • Chassis ➜ Brakes ➜ EPB Service Mode
    via Service Mode Plus: Drive Unit ➜ Rear Drive Unit Replacement ➜ Release / Re-Engage Emergency Parking Brake    , click Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Chock the rear wheels.
    Informational PurposesAn informational icon, calling your attention
    Note
    Click the X at the top right of window to close once complete.
  9. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  10. Disconnect MV power. See Disconnect MV Power.
  11. Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  12. Release the connector lock, and then disconnect the RH rear EPB harness.
  13. Remove the bolt that attaches the RH rear brake line to the upper control arm.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  14. Remove the bolts (x2) that attach the RH rear brake caliper to the vehicle, and then use an S-hook hang the caliper aside.
    150 Nm (110.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Route the caliper hose so that it does not get caught on the stabar assembly.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  15. Remove the RH rear brake rotor.
    Informational PurposesAn informational icon, calling your attention
    Note
    The rotor will be loose after the caliper is released.
  16. Use a jack to simulate ride height on the RH rear suspension.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    DO NOT skip this step. Failure to perform this step may result in personal injury.
    Informational PurposesAn informational icon, calling your attention
    Note
    This is to release tension from the upper control arm.
  17. Remove and discard the nut that attaches the RH rear upper control arm to the knuckle.
    150 Nm (110.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  18. Use the jack to lower the RH rear ride height back to hanging position.
  19. Disconnect the harness electrical connectors (x2) from the RH rear air spring module, and then release the harness from the grommets (x2).
  20. Remove the bolts (x3) that attach the RH lower control arm shield to the vehicle, and then remove the shield from the vehicle.
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  21. Remove and discard the nuts (x2) that attach the RH rear air spring module to the lower control arm.
    140 Nm (103.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  22. Repeat step 12 through step 21 for the LH side of the vehicle.
  23. Raise the vehicle fully.
  24. Remove the bolts (x8) and clips (x6) that attach the mid aeroshield to the vehicle, and then remove the aeroshield from the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 13 mm socket
    • 10 mm socket
  25. Remove the rear aeroshield. See Undertray - Rear Aeroshield (Remove and Install).
  26. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
  27. Disconnect the rear drive unit and front drive unit HV harnesses from the HV battery.
    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 upwards.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the alignment tabs on the rear drive unit header are not damaged.
  28. Remove the leather over gloves and HV insulating gloves.
  29. Release the connector locks, and then disconnect the dual motor rear subframe harness electrical connectors (x3) from the rear fascia harness.
  30. Remove the bolts (x14) and release the clips (x12) and tabs (x16) that attach the rear diffuser to the vehicle, and then remove the diffuser from the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • Torx T30 socket
  31. Remove the bolts (x6) that attach the rear diffuser brackets to the vehicle, and then let the brackets hang.
    30 Nm (22.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  32. Release the connector lock, and then disconnect the rear steering gear harness from the subframe.
  33. Position a coolant drain container underneath the RH rear of the HV battery.
  34. Release the spring, disconnect the RDU return hose from the PT return hose, and then plug both fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull back the wheel liner as needed.
  35. Release the clamp clip.
  36. Remove coolant hose from rear inverter lower fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose clip, Plug both ends, Release clip, Use a long flathead to release clip on hose and release hose
  37. Remove the coolant drain container from underneath the vehicle.
  38. Lower the vehicle partially.
  39. Position the powertrain lift under the rear subframe.
  40. Connect shop air supply to the powertrain table.
  41. Raise the powertrain lift to the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the height setting of the hoist can be reached with the powertrain lift height limit.
  42. Safely secure the rear subframe onto the powertrain lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure subframe to powertrain table and fixture
  43. Remove the bolts (x4) that attach the rear subframe to the vehicle.
    355 Nm (261.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  44. Lower the subframe table to access the breather tube.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful with the RDU coolant hoses and breather line. The subframe jig assembly will need to be maneuvered to prevent coolant lines getting caught. Access the breather from the LH rear wheel well.
  45. Disconnect the RDU breather tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    Press the tabs (x2) inward and pull the breather upwards.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the clip from the RDU casing.
  46. Fully lower the subframe table.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful with the RDU coolant hoses. The subframe table will need to be moved back to prevent coolant lines getting caught. Make sure the drive unit breather line is not caught.
  47. Disconnect the air supply from the subframe lifting tool.
  48. Release the spring clip, disconnect the coolant hose from the rear inverter upper fitting, and then plug both fittings.
  49. Release the spring clips, disconnect the coolant hoses (x2) from the chiller, and then plug all the fittings.
  50. Release the connector lock, disconnect the RDU HV cable from the RDU, and then move the connector aside.
  51. Remove the bolts (x4) and release the clip that attach the RDU HV cable assembly to the vehicle, and then remove the cable assembly from the vehicle.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  52. Release the connector lock, disconnect the RDU logic connector, and then move the connector aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to get coolant into the connector.
  53. Release the connector locks and disconnect the LV harness electrical connectors (x2), and then release the clips that attach the harness to the RDU.
  54. Release the connector lock, and then disconnect the RDU oil pump electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab, and then gently pull the connector to disconnect.
  55. Install the cable axle removal kit, and then release the LH rear halfshaft from the RDU. Repeat this step for the RH rear halfshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wrap the cable around the inner joint, and then tighten with the U-bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand-tighten the nuts.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  56. Attach the RDU sling eyelets (x3).
  57. Attach the drive unit sling to the gantry.
  58. Remove the RDU mounting bolts (x2).
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • E18 socket
  59. Remove the RDU gearcase mount bolts (x2).
    110 Nm (81.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the drive unit rearward if the tools become jammed once released.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  60. With assistance, raise the sling to lift the drive unit out of the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the drive unit rearwards to clear steering gear.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate as required to clear the halfshafts.
  61. Position the empty drive unit crate below the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the sling as needed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pallet if no empty crate is available.
  62. Lower the drive unit into the drive unit crate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pallet if no empty crate is available.
  63. Remove the lifting sling from the drive unit.

Install

  1. Attach the lifting sling to the new drive unit.
  2. Attach the drive unit sling to the gantry.
  3. Raise the drive unit out of the drive unit crate.
  4. With assistance, lower the sling to position the drive unit into the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the drive unit to clear the steering gear.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the drive unit as needed to clear the halfshafts.
  5. Install the RDU gearcase mount bolts (x2).
    110 Nm (81.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the drive unit as needed to align.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  6. Install the RDU mounting bolts (x2).
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • E18 socket
  7. Remove the drive unit sling from the gantry.
  8. Remove the sling from the RDU.
  9. Install the LH and RH rear halfshafts into the RDU.
    Figure 1. LH shown; RH similar
  10. Connect the RDU oil pump electrical connector, and then secure the connector lock.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the connector is fully seat before engaging the connector lock.
  11. Install clips (x3) that attach the LV harness to the RDU, and then connect the electrical connectors (x2) and engage the connector locks.
  12. Connect the RDU logic connector, and then engage the connector lock.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the lever is fully engaged.
  13. Position the RDU HV cable assembly into the vehicle, and then install the bolts (x4) and secure the clip that attach the cable assembly to the vehicle.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  14. Connect the RDU HV connector, and then engage the locking tab.
  15. Remove the hose plugs, connect the coolant hoses (x2) to the chiller, and then secure the spring clips.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to verify the hose if fully seated.
  16. Secure the rear inverter coolant hose to the gearbox housing.
  17. Connect the rear inverter cooler hose, and then secure the spring clip.
  18. Position the subframe lifting tool with subframe assembly under the vehicle.
  19. Connect shop air supply to the powertrain table.
  20. With assistance, raise the drive unit until sufficient access is available to the breather.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to damage components while raising subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the coolant lines above the HV battery lip.
  21. Connect the RDU breather tube and install the clip onto the RDU casing.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the tabs (x2) are fully engaged.
  22. With assistance, fully raise the rear drive unit and subframe into position.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to damage components while raising subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the coolant lines above the HV battery lip.
  23. Install and hand-tighten the bolts (x4) that attach the rear subframe to the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  24. Torque the bolts (x4) that attach the rear subframe to the vehicle.
    355 Nm (261.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  25. Remove the tie downs from the powertrain lift.
  26. Lower the powertrain table from the subframe, and then move it away from the vehicle.
  27. Connect the rear steering gear harness to the subframe, and then engage the connector lock.
  28. Position the coolant drain container underneath the RH rear of HV battery.
  29. Remove the hose plugs, connect the RDU return hose to the PT return hose, and then secure the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull back the wheel liner as needed.
  30. Remove coolant hose from rear inverter lower fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose clip, Plug both ends, Release clip, Use a long flathead to release clip on hose and release hose, Perform push-pull-push test
  31. Remove the coolant drain container from underneath the vehicle.
  32. Connect the rear drive unit and front drive unit HV harnesses to the HV battery, and then engage the connector locks.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the alignment tabs on the rear drive unit header are not damaged.
  33. Raise the rear diffuser brackets into the position, and then install the bolts (x6).
    30 Nm (22.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  34. Position the rear diffuser to the vehicle, and then install the bolts (x14) and secure the clips (x12) and tabs (x16) that attach the diffuser to the vehicle.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • Torx T30 socket
  35. Connect the dual motor rear subframe harness electrical connectors (x3) to the rear fascia harness.
  36. Install the rear aeroshield. See Undertray - Rear Aeroshield (Remove and Install).
  37. Position the mid aero shield onto the vehicle, and then install the bolts (x8) and clips (x6) that attach the aeroshield to the vehicle.
    70 Nm (51.6 lbs-ft)
    28 Nm (20.6 lbs-ft)
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply Loctite 222 onto the mid aero shield bolts, and then install the fasteners.
    Informational PurposesAn informational icon, calling your attention
    Note
    The torque value are as follows:
    • 15 mm bolts (x3) are torqued to 70 Nm
    • 13 mm bolts (x3) are torqued to 28 Nm
    • 10 mm bolts (x2) are torqued to 6 Nm
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 13 mm socket
    • 10 mm socket
  38. Lower the vehicle partially.
  39. Install new nuts (x2) that attach the RH rear air spring module to the lower control arm.
    140 Nm (103.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  40. Use a jack to simulate ride height on the RH rear suspension.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    DO NOT skip this step. Failure to perform this step may result in personal injury.
    Informational PurposesAn informational icon, calling your attention
    Note
    This is to release tension from the upper control arm.
  41. Install a new nut that attaches the RH rear upper control arm to the knuckle.
    150 Nm (110.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Counter-hold the joint to install nut.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the brake hose is properly routed.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  42. Use the jack to lower the RH rear ride height back to hanging position.
  43. Connect the electrical connectors (x2) to the RH rear air spring module, and then secure the harness to the grommets (x2).
  44. Position the RH lower control arm shield to the vehicle, and then install the bolts (x3) that attach the shield to the vehicle.
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  45. Position the RH rear brake rotor onto hub.
  46. Position the RH rear brake caliper to the vehicle, and then install the bolts (x2).
    150 Nm (110.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Route the caliper hose so that it does not get caught on the stabar assembly.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
  47. Connect the RH rear EPB harness electrical connector, and then engage the connector lock.
  48. Install the bolt that attaches the RH rear brake line to the upper control arm.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  49. Repeat step 39 through step 48 for the LH side of the vehicle.
  50. Install the LH and RH rear wheels and install and hand-tighten the lug nuts.
  51. Lower the vehicle until tires are touching the ground.
  52. Perform cooling system vacuum refill. See Cooling System (Vacuum Refill).
  53. Connect MV power. See Disconnect MV Power.
  54. On the vehicle touchscreen, navigate to Service mode > Diagnostics > Thermal to access the thermal system routines.
    Informational PurposesAn informational icon, calling your attention
    Note
    Authorize routines by holding the right turn signal, and then depressing the brake pedal for 10 seconds with key on phone dock.
  55. Tap Start Coolant Air Purge, tap Run, and allow the routine to complete.
  56. Inspect the coolant level and top off as necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the fluid level is at the Max line.
  57. Install the coolant bottle cap.
  58. Re-establish vehicle connection to Toolbox 3.
  59. In Toolbox, click the Actions tab, and then search for "EPB".
  60. Click PROC_EPB_X_SERVICE-MODEvia Toolbox: (link)via Service Mode:
    • Chassis ➜ Brakes ➜ EPB Service Mode
    • Chassis ➜ Brakes ➜ EPB Service Mode
    • Chassis ➜ Brakes ➜ EPB Service Mode
    via Service Mode Plus: Drive Unit ➜ Rear Drive Unit Replacement ➜ Release / Re-Engage Emergency Parking Brake    , click Run, and allow the routine to complete.
  61. Torque the LH and RH rear wheel nuts.
    205 Nm (151.2 lbs-ft)
  62. Install the LH and RH rear wheel caps. See Wheel Cover - Front - LH (Remove and Install).
  63. Close the powered frunk.
  64. Raise the LH front window and close the LH front door.
  65. Perform test drive.
    Informational PurposesAn informational icon, calling your attention
    Note
    Drive a minimum speed of 25mph in a straight line and check for excessive pull. Verify the steering wheel is centered when vehicle is driving straight. Determine whether an alignment is recommended. Add correction code 00040100 as needed.