08/10/2024 17:33:48

HV Harness - Rear Drive Unit - LH (Tri Motor) (Remove and Replace)

Correction code N/A FRT 2.82 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
Open powered front trunk

Note
Via exterior switch or UI
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
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Start Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain
via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid 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
Connect to vehicle using Toolbox 3.0

Note
Vehicle OBD II connection is integrated into drivers lower IP cover, 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)
Select "Actions" and search for "EPB"
Select
PROC_EPB_X_SERVICE-MODE
via 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 routine to complete
Note
Choose 'BOTH' under "EPB Selection", Choose 'START' under "Action Selection", Chock wheel if necessary, Select ‘X’ at top right of window to close once complete
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
Remove rear underhood apron

Note
9x clips
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 rear 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
Remove RH rear 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 rear wheel nuts

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

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

Note
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

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

Note
6x nuts, 21mm, 205 Nm
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 Mid-aero shield

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

Note
5x bolts, 10mm, 6 Nm, 2x guides
Remove rear diffuser

Note
6x bolts, 10mm, 6 Nm, 8x bolts, T30, 6 Nm, 6x clips, 6x harness secure clips, 16x tabs
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. 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
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 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

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 rear subframe harness from rear fascia harness

Note
3x 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
Make sure the height setting of the hoist can be reached with the 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 LH RDU inverter to chiller hose

Note
2x spring clips, Plug coolant connections as needed
Disconnect LHS RDU 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 LHS RDU harness

Note
6x bolts, 10mm, 12 Nm
Install LHS RDU harness

Note
6x bolts, 10mm, 12 Nm
Connect LHS RDU 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 LH RDU inverter to chiller hose

Note
2x spring clips, Remove plugs as needed
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 rear subframe bolts

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 tri motor rear subframe harness onto rear fascia harness

Note
3x connectors
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
Connect LHS 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 rear diffuser

Note
6x bolts, 10mm, 6 Nm, 8x bolts, T30, 6 Nm, 6x clips, 6x harness secure clips, 16x tabs
Install rear aero shield

Note
5x bolts, 10mm, 6 Nm, 2x guides
Install Mid-aero shield

Note
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

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
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
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
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
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 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
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
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

Note
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

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

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

Note
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

Note
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

Note
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

Note
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

Note
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
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 "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
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 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"
Raise LH front window
Close LH front door

Cybertruck Service Manual

HV Harness - Rear Drive Unit - LH (Tri Motor) (Remove and Replace)

Figure 1

Figure 2

Figure 3