24/04/2024 08:37:22

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

Correction code 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

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 LH front door

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

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Set air suspension to "Jack Mode"
Place vehicle into Service Mode Plus using Vehicle Ops App

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Vehicle Ops App > Login > Shared Fleet > Search VIN > Service Mode Plus
Unlock vehicle gateway

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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 rear drive unit replacement panel via Service Mode Plus UI

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Controls > Service Mode > High Voltage > Procedures > Rear Drive Unit Replacement
Run 'Start Coolant Fill/Drain' routine

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Via Rear Drive Unit Replacement Dashboard, Ensure result is 'Passed'
Run 'Release Emergency Parking Brake' routine

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Via Rear Drive Unit Replacement Dashboard, Ensure result is 'Passed'
Power down vehicle via UI

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Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Open powered front trunk

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Via exterior switch or UI
Remove rear underhood apron

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9x clips
Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release

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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 rear wheel cap

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1x cap, 8x clips, Use both hands to firmly pull wheel cap to release clips, Cap may remove with or without mounting ring attached
Remove RH rear wheel cap

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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 rear wheel nuts

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6x nuts, 21mm, 205 Nm
Loosen LH rear wheel nuts

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6x nuts, 21mm, 205 Nm
Raise vehicle partially and lower onto locks

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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
Remove LH rear wheel

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6x nuts, 21mm, 205 Nm
Remove RH rear wheel

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6x nuts, 21mm, 205 Nm
Disconnect RH rear EPB harness

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

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

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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

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

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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 nut securing RH rear upper control arm to knuckle

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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

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

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

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

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

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

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

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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 nut securing LH rear upper control arm to knuckle

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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

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

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

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

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

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

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6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Remove rear aeroshield

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7x bolts, 10mm, 6 Nm, Slide out from under mid aeroshield
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

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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 required. If 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 damaged. Make 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

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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
Disconnect dual motor rear subframe harness from rear fascia harness

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3x connectors, Pull red tabs before releasing connectors
Remove rear diffuser

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6x bolts, 10mm, 6 Nm, 8x bolts, T30, 6 Nm, 6x clips, 6x harness secure clips, 16x tabs
Release rear diffuser brackets and set aside

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6x bolts, 13mm, 30 Nm, 4x tabs, Let brackets hang
Disconnect rear steering gear harness from subframe

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1x connector, Release red locking tab
Position coolant drain container underneath RH rear of HV battery
Disconnect RDU return hose from PT return hose

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1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed
Remove RDU coolant hose from rear inverter

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1x clip, 1x hose clip, Plug both ends, Release clip, Use a long flathead to release clip on hose and release hose
Remove coolant drain container from underneath vehicle
Lower vehicle partially and set lift onto locks

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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

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Make sure the height setting of the hoist can be reached with the powertrain lift height limit
Safely secure rear subframe onto powertrain lift

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

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

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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

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

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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 RDU supply hose from rear inverter

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1x spring clip, Plug both ends after disconnecting
Disconnect coolant hoses from chiller

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2x spring clips, Plug both ends
Disconnect RDU HV cable from RDU

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1x connector, Disengage locking tab then release connector body and move aside
Remove RDU HV cable assembly

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4x bolts, 10mm, 4 Nm, 1x clip
Disconnect RDU logic connector

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1x connector, Release locking tab, Do not get coolant ingress into this connector, Move aside as needed
Remove LV harness from RDU

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2x connectors, Release red locking tabs, 3x clips
Disconnect RDU oil pump

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1x connector, Release connector lock, depress and gently pull
Release LH rear halfshaft from RDU

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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

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1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint then tighten with U-bolt
Attach RDU sling

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3x eyelets
Attach drive unit sling to gantry
Remove RDU mounting bolts

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2x bolts, E18, 85 Nm
Remove RDU gearcase mount bolts

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2x bolts, 18mm, 110 Nm, Shift drive unit rearward if tools become jammed once released
Raise sling to lift drive unit out of subframe

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Recommend assistance, Pull drive unit rearwards to clear steering gear, Rotate as required to clear halfshafts
Position empty drive unit crate below drive unit

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May need to adjust sling, Use pallet if no empty crate available
Lower drive unit into drive unit crate

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Use pallet if no empty crate available
Remove lifting sling from drive unit

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3x hooks
Attach drive unit sling tool to drive unit

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3x hooks
Secure drive unit sling to gantry
Raise drive unit out of drive unit crate
Lower sling to position drive unit into subframe

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Recommend assistance, Position drive unit to clear steering gear, Rotate as required to clear halfshafts
Install RDU gearcase mount bolts

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2x bolts, 18mm, 110 Nm, Shift drive unit as required to align
Install RDU mounting bolts

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2x bolts, E18, 85 Nm
Remove drive unit sling from gantry
Remove sling from RDU

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3x eyelets
Install LH rear halfshaft into RDU
Install RH rear halfshaft into RDU
Connect RDU oil pump

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1x connector, Engage locking tab
Install LV harness onto RDU

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2x connectors, Secure red locking tabs, 3x clips
Connect RDU logic connector

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1x connector, Inspect connector housing on harness side and inverter side for presence of coolant or any debris, Verify lever is fully engaged
Install RDU HV cable assembly

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4x bolts, 10mm, 4 Nm, 1x clip
Connect RDU HV connector

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1x connector, Inspect connector housing on harness side and inverter side for presence of coolant or any debris, Engage locking tab
Connect coolant hoses onto chiller

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2x spring clips, remove plugs and connect, Perform push-pull test
Secure rear inverter coolant hose to gearbox housing

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1x hose clip
Install rear inverter cooler hose

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1x spring 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

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

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

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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

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

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

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Release subframe to powertrain table and fixture
Lower powertrain table from subframe and move away from vehicle
Connect rear steering gear harness

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1x connector, Engage red locking tab
Position coolant drain container underneath RH rear of HV battery
Connect RDU return hose to PT return hose

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1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Remove plugs
Install coolant hose onto rear inverter lower fitting

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1x spring clip, Remove plugs from both ends, Perform push-pull-push test
Remove coolant drain container from underneath vehicle
Connect RDU HV harness

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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
Secure rear diffuser brackets

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6x bolts, 13mm, 30 Nm, 4 tabs
Install rear diffuser

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6x bolts, 10mm, 6 Nm, 8x bolts, T30, 6 Nm, 6x clips, 6x harness secure clips, 16x tabs
Install dual motor rear subframe harness onto rear fascia harness

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3x connectors, Secure red tabs
Install rear aeroshield

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7x bolts, 10mm, 6 Nm, Slide under mid aeroshield, Apply Loctite 222 onto mid aeroshield bolts and install fasteners
Install Mid-aero shield

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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
Lower vehicle partially and set lift onto locks

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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
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
Use jack to lower LH rear ride height back to hanging position

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Lower jack to let suspension hang
Secure harness to LH rear active dampener

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2x connectors, 2x grommets
Install LH rear lower control arm aeroshield

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3x bolts, 10mm, 7 Nm
Position LH rear brake rotor

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

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

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

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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
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
Use jack to lower RH rear ride height back to hanging position

Note
Lower jack to let suspension hang
Secure harness to RH rear active dampener

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2x connectors, 2x grommets
Install RH rear lower control arm aeroshield

Note
3x bolts, 10mm, 7 Nm
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

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

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1x bolt, 10 mm, 10 Nm
Install RH rear wheel

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

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
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

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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

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

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

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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

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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

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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

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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

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Move coolant drain & fill cart away from vehicle
Remove coolant container from inside underhood area
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
Run 'Stop Coolant Fill/Drain' routine

Note
Via Rear Drive Unit Replacement dashboard, Ensure result is 'Passed'
Run 'CAN Redeploy' routine

Note
Via Rear Drive Unit Replacement dashboard, CAN redeploy will start immediately
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
Run 'Thermal Performance Test' routine

Note
Via Rear Drive Unit Replacement dashboard, Ensure result is 'Passed'
Exit Service Mode

Note
Via UI > Service > Exit, Press and hold "Exit Service Mode" button
Torque RH rear wheel nuts

Note
6x nuts, 21mm, 205 Nm
Torque LH rear wheel nuts

Note
6x nuts, 21mm, 205 Nm
Install RH rear 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 LH rear 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
Close powered front trunk

Note
Via exterior switch or UI
Raise LH front window
Close LH front door
Perform test drive

Note
Perform a validation test drive after repair. Drive 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 recommended. Add correction code 00040100 as needed