28/08/2024 09:25:24

Chassis and Subframes - Rear Subframe (Dual Motor) (Remove and Replace)

Correction code NA 3.78 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.

Open the LH front door and lower the LH front window.
Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
Unlock the vehicle Gateway. See Gateway (Unlock).
On the vehicle touchscreen, navigate to UI > Service Mode > High Voltage > Procedures > Rear Drive Unit Replacement to access the rear drive unit replacement panel.
Tap Start Coolant Fill/Drain, and then tap Run.

Note
Make sure the result is "Passed".
Tap Release Emergency Parking Brake, and then tap Run.

Note
Make sure the result is "Passed".
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Disconnect MV power. See Disconnect MV Power.
Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
Disconnect RH rear EPB harness

Note
1x connector, Release locking tab
Release RH rear brake line from upper control arm

Note
1x bolt, 10mm, 10 Nm
Remove RH rear brake caliper and set aside

Note
2x bolts, 21 mm, 150 Nm, Hang caliper from body if not fully removing, Route caliper hose so that it does not get caught on stabar assembly
Remove RH rear brake rotor

Note
Rotor will be loose until caliper is installed
Use jack to simulate ride height on RH rear suspension

Note
Raise jack to simulate ride height, This is to release tension from the upper control arm which will be removed next later steps, DO NOT skip this you run into the risk of hurting yourself
Remove RH rear toe link from RH rear knuckle

Note
1x nut, 21mm, 170 Nm, Counter hold ball joint, Discard nyloc nut after removal
Remove nut securing RH rear upper control arm to knuckle

Note
1x nylon nut, 21 mm, 150 Nm, Discard nut after removal, Place support stand below suspension to ease removal
Use jack to lower RH rear ride height back to hanging position

Note
Lower jack to let suspension hang
Release harness from RH rear air spring module

Note
2x connectors, 1x grommet
Remove RH rear lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
Remove nuts securing RH rear air spring module to lower control arm

Note
2x nylon nut, 21 mm, 140 Nm, Discard nuts after removal
Disconnect EPB harness connector from LH rear brake caliper

Note
1x connector, Release locking tab
Release LH rear brake line from upper control arm

Note
1x bolt, 10mm, 10 Nm
Remove LH rear brake caliper and set aside

Note
2x bolts, 21 mm, 150 Nm, Hang caliper from body if not fully removing, Route caliper hose so that it does not get caught on stabar assembly
Remove LH rear brake rotor

Note
Rotor will be loose until caliper is installed
Use jack to simulate ride height on LH rear suspension

Note
Raise jack to simulate ride height, This is to release tension from the upper control arm which will be removed next later steps, DO NOT skip this you run into the risk of hurting yourself
Remove LH rear toe link from LH rear knuckle

Note
1x nut, 21mm, 170 Nm, Counter hold ball joint, Discard nyloc nut after removal
Remove nut securing LH rear upper control arm to knuckle

Note
1x nylon nut, 21 mm, 150 Nm, Discard nut after removal, Move brake hose aside to avoid damage, Use caution when releasing rear upper control from knuckle
Use jack to lower LH rear ride height back to hanging position

Note
Lower jack to let suspension hang
Release harness from LH rear air spring module

Note
2x connectors, 1x grommet
Remove LH rear lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
Remove nuts securing LH rear air spring module to lower control arm

Note
2x nylon nut, 21 mm, 140 Nm, Discard nuts after removal
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
Remove the rear aeroshield. See Undertray - Rear Aeroshield (Remove and Install).
Remove the rear diffuser. See Undertray - Diffuser (Remove and Install).
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.
Put on HV insulating gloves and leather over gloves
Remove clips securing AC compressor HV harness

Note
3x clips
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
Disconnect RDU HV harness

Note
1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged
Remove leather over gloves and HV insulating gloves
Position coolant drain container underneath RH rear of HV battery
Remove front lower clips securing RH rear wheel arch liner

Note
3x clips
Disconnect RDU return hose from PT return hose

Note
1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed
Disconnect RDU supply hose from HV battery

Note
1x spring clip, Plug coolant connections as needed
Remove coolant drain container from underneath vehicle
Disconnect rear steering gear harness from subframe

Note
1x connector, Release red locking tab
Disconnect DM rear subframe harness from rear fascia harness

Note
3x connectors, Release red tabs then disconnect connectors
Release rear diffuser brackets and set aside

Note
6x bolts, 13mm, 30 Nm, 4x tabs, Let brackets hang
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
Position powertrain lift under rear subframe
Connect shop air supply to powertrain table
Raise powertrain lift to rear subframe

Note
3x dowels, Make sure height on hoist can be reached with powertrain lift height limit
Safely secure rear subframe onto powertrain lift

Note
Secure subframe to powertrain table and fixture
Remove bolts securing rear subframe to body

Note
4x bolts, 24mm, 355 Nm
Lower subframe table to access breather tube

Note
Use caution with RDU coolant hoses and breather line, Subframe jig assembly will need to be maneuvered to prevent coolant lines getting caught, Access breather from LH rear wheel well
Disconnect RDU breather tube

Note
2x tabs, 1x clip, Press tabs inward and pull breather up, Release clip from RDU casing
Fully lower subframe table

Note
Use caution with RDU coolant hoses, Subframe table will need to be moved back to prevent coolant lines getting caught, Ensure DU breather line is not caught
Disconnect air supply from subframe lifting tool
Remove clip securing RSA jumper harness to RDU HV harness

Note
1x clip
Release RDU HV harness bracket from subframe

Note
1x bracket, 2x bolts, 10mm, 12 Nm, Set bracket aside
Remove RSA and toe link assembly

Note
4x bolts, 18 mm, 120 Nm, 1x connector, Release locking tab
Release RDU supply and return hose from subframe

Note
4x clips
Remove bolt securing ground strap to rear subframe

Note
1x bolt, 10mm, 10 Nm
Release LH rear halfshaft from RDU

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint then tighten with U-bolt
Release RH rear halfshaft from RDU

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint then tighten with U-bolt
Remove rear stabilizer bar and link assembly

Note
2x links, 4x bolts, 15mm, 50 Nm, 2x nuts, 15mm, 45 Nm, Remove clip securing RDU harness as needed
Release LH chassis corner harness from subframe

Note
2x clips
Release RH chassis corner harness from subframe

Note
2x clips
Remove LH control arm, axle, and knuckle as an assembly

Note
4x bolts, 21mm, 185 Nm, Recommend assistance
Remove RH control arm, axle, and knuckle as an assembly

Note
4x bolts, 21mm, 185 Nm, Recommend assistance
Remove clips securing RDU harness to subframe

Note
7x clips
Remove rear steering actuator harness

Note
3x clips
Secure sling onto RDU

Note
3x black shackles, 3x eyelets
Secure sling onto gantry

Note
3x black shackles, 3x eyelets, Make sure components are positioned to prevent binding
Remove fasteners securing RDU to subframe

Note
2x bolts, 16mm, 85 Nm, 2x nuts, 18mm, 95 Nm, 3x mount masses
Raise RDU from subframe

Note
Recommend assistance, Do NOT raise all at once, Pry and release bushing mounts from subframe studs, Avoid damaging subframe studs
Position pallet below drive unit

Note
May need to adjust sling
Lower drive unit onto pallet
Remove rear subframe from drive unit jack

Note
Recommend assistance
Install rear subframe on to drive unit jack

Note
Recommend assistance, Revision D will come with 5x steel blocks, If replacement subframe is revision D then do not install mount masses
Raise RDU from pallet

Note
3x black shackles, 3x eyelets
Lower RDU onto subframe

Note
Recommend assistance, Do NOT lower all at once, Pry and position bushing mounts onto subframe studs, Avoid damaging subframe studs
Install fasteners securing RDU to subframe

Note
2x bolts, E18, 105 Nm, 2x nuts, 18mm, 95 Nm, If replacement subframe is revision D then do not install mount masses, Install new bolts, Torque to updated specification
Release sling from gantry

Note
3x black shackles, 3x eyelets
Release sling from RDU

Note
3x black shackles, 3x eyelets
Install clips securing RDU harness to subframe

Note
7x clips
Install steering actuator harness

Note
3x clips
Install RH control arm, axle, and knuckle as an assembly

Note
4x bolts, 21mm, 185 Nm, Recommend assistance, Lower control arm may clash with powertrain lift, Shift subframe as needed
Install LH control arm, axle, and knuckle as an assembly

Note
4x bolts, 21mm, 185 Nm, Recommend assistance, Lower control arm may clash with powertrain lift, Shift subframe as needed
Secure RH chassis corner harness onto subframe

Note
2x clips
Secure LH chassis corner harness onto subframe

Note
2x clips
Install rear stabilizer bar and link assembly

Note
2x links, 4x bolts, 15mm, 50 Nm, 2x nuts, 15mm, 45 Nm, Secure clip securing RDU harness as needed
Install LH rear halfshaft into RDU
Install RH rear halfshaft into RDU
Install bolt securing ground strap to rear subframe

Note
1x bolt, 10mm, 10 Nm
Secure RDU supply and return hose onto subframe

Note
4x clips
Install RSA and toe link assembly

Note
4x bolts, 18 mm, 120 Nm, 1x connector, Secure locking tab
Secure RDU HV harness bracket onto subframe

Note
1x bracket, 2x bolts, 10mm, 12 Nm
Install clip securing RSA jumper harness to RDU HV harness

Note
1x clip
Position subframe lifting tool with subframe assembly under vehicle
Connect air supply to subframe lifting tool
Raise drive unit until sufficient access is available to breather

Note
Recommend assistance, Use caution to not damage components while raising subframe, Position coolant lines above HV battery lip
Connect RDU breather tube

Note
2x tabs, 1x clip, Install clip onto RDU casing, Verify tabs are fully engaged
Fully raise rear drive unit and subframe into position

Note
Recommend assistance, Use caution to not damage components while raising subframe, Position coolant lines above HV battery lip
Loosely install bolts securing rear subframe to body

Note
4x bolts, 24mm, Hand Tight, Start bolts by hand before using power tools
Torque bolts securing rear subframe to body

Note
4x bolts, 24mm, 355 Nm
Remove rear subframe tie downs from powertrain lift

Note
Release subframe to powertrain table and fixture
Lower powertrain table from subframe and move away from vehicle
Secure rear diffuser brackets

Note
6x bolts, 13mm, 30 Nm, 4 tabs
Connect DM rear subframe harness onto rear fascia harness

Note
3x connectors, Secure red tabs
Connect rear steering gear harness

Note
1x connector, Engage red locking tab
Position coolant drain container underneath RH rear of HV battery
Connect RDU supply hose onto HV battery

Note
1x spring clip, Remove plugs as needed
Connect RDU return hose to PT return hose

Note
1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Remove plugs
Install front lower clips securing RH rear wheel arch liner

Note
3x clips
Remove coolant drain container from underneath vehicle
Connect RDU HV harness

Note
1x connector, Verify lever is upright and in open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
Install clips securing AC compressor HV harness

Note
3x clips
Install the rear diffuser. See Undertray - Diffuser (Remove and Install).
Install the rear aeroshield. See Undertray - Rear Aeroshield (Remove and Install).
Install the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
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 nuts securing LH rear air spring module to lower control arm assembly

Note
2x nylon nut, 21 mm, 140 Nm, Install new nylon nuts
Install LH rear lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
Secure harness to LH rear active dampener

Note
2x connectors, 2x grommets
Use jack to simulate ride height on LH rear suspension

Note
Raise jack to simulate ride height, This is to release tension from the upper control arm which will be removed next later steps, DO NOT skip this you run into the risk of hurting yourself
Install nut securing LH rear upper control arm to knuckle

Note
1x nylon nut, 21 mm, 150 Nm, Install new nylon nut, Counter-hold joint to install nut, Support suspension to ease installation, Ensure brake hose is properly routed
Install LH rear toe link onto LH rear knuckle

Note
1x nut, 21mm, 170 Nm, Install new Nyloc nut
Use jack to lower LH rear ride height back to hanging position

Note
Lower jack to let suspension hang
Position LH rear brake rotor

Note
Rotor will be loose until caliper is installed
Install LH rear brake caliper onto LH rear knuckle

Note
2x bolts, 21mm, 150 Nm
Connect EPB harness connector to LH rear brake caliper

Note
1x connector, Engage locking tab
Install LH rear brake line onto upper control arm

Note
1x bolt, 10 mm, 10 Nm
Install nuts securing RH rear air spring module to lower control arm assembly

Note
2x nylon nut, 21 mm, 140 Nm, Install new nylon nuts
Install RH rear lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
Secure harness to RH rear active dampener

Note
2x connectors, 2x grommets
Use jack to simulate ride height on RH rear suspension

Note
Raise jack to simulate ride height, This is to release tension from the upper control arm which will be removed next later steps, DO NOT skip this you run into the risk of hurting yourself
Install nut securing RH rear upper control arm to knuckle

Note
1x nylon nut, 21 mm, 150 Nm, Install new nylon nut, Counter-hold joint to install nut, Support suspension to ease installation
Install RH rear toe link onto RH rear knuckle

Note
1x nut, 21mm, 170 Nm, Install new Nyloc nut
Use jack to lower RH rear ride height back to hanging position

Note
Lower jack to let suspension hang
Position RH rear brake rotor

Note
Rotor will be loose until caliper is installed
Install RH rear brake caliper onto RH rear knuckle

Note
2x bolts, 21mm, 150 Nm
Connect RH rear EPB harness

Note
1x connector, Engage locking tab
Install RH rear brake line onto upper control arm

Note
1x bolt, 10 mm, 10 Nm
Install the LH and RH rear wheels

Note
6x nuts, 21mm, 205 Nm
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 cooling system vacuum refill. See Cooling System (Vacuum Refill).
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
Hold brake pedal and select park on UI to disable EPB service mode
Re-establish vehicle connection to Toolbox 3

Note
Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)
Run 'Stop Coolant Fill/Drain' routine

Note
Via Rear Drive Unit Replacement dashboard, Ensure result is 'Passed'
Run 'Coolant Air Purge' routine

Note
Via Rear Drive Unit Replacement dashboard, 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
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
Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Torque the LH and RH rear wheel nuts

Note
6x nuts, 21mm, 205 Nm
Install LH and RH rear wheel caps

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
Close the powered frunk.
Disconnect Toolbox and remove the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).
Exit Service Mode. See 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.
Perform test drive

Note
Perform a validation test drive after repairDrive a minimum speed of 25mph, Drive 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 recommendedAdd correction code 00040100 as needed

Cybertruck Service Manual

Chassis and Subframes - Rear Subframe (Dual Motor) (Remove and Replace)

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