23/09/2024 01:26:54

Inverter - Front Drive Unit (3DU) (Remove and Replace)

Correction code 3920010012 FRT 3.30 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.

  • 2024-02-27: Updated gearbox fluid to KAF 1.
  • 2023-12-11: Updated last step with cross reference to Alignment Requirement Tables.
  • 1076971-02-A - WRENCH, TORQUE+ANGLE, 1/4" DR

Remove

  1. Verify that the vehicle firmware is version feature/poppyseed-32-5 or later. Update the vehicle software if this is not the case.
  2. Raise and support the vehicle. See GUID-0ECF2493-88F6-48E9-ADBB-9AE1D52E217C.html.
  3. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
    Informational PurposesAn informational icon, calling your attention
    Note
    Upon successful connection, Service Mode Plus will be enabled, and the "Service Mode Plus" watermark will appear on the touchscreen.
  4. Enable Service Mode Plus. See Service Mode Plus.
  5. On the touchscreen, touch Service Mode Plus > High Voltage > Procedures > Front Drive INVERTER Replacement, then perform the following steps.
    1. Select Store Bootloader Data, select Run, then allow the routine to complete.
    2. Select Store Application Data, select Run, then allow the routine to complete.
    3. Select Start Thermal Fluid Fill/Drain (Coolant only), select Run, and then allow the routine to complete.
  6. Remove the front drive unit mount. See Mount Assembly - Front Drive Unit - LH (3DU) (Remove and Replace).
  7. Remove the inverter to oil cooler hose. See Hose - Front Drive Unit to Oil Cooler (Remove and Replace).
  8. Remove the front drive unit inlet hose. See Hose - Inlet - Front Drive Unit Inverter (Remove and Replace).
  9. Disconnect PT return tube from FDU inverter inlet hose.
  10. Disconnect FDU HV harness connector.
  11. Remove bolt securing FDU ground strap to FDU.
  12. Release FDU ground strap harness clip from FDU.
  13. Disconnect FDU PT return hose from FDU heat exchanger.
  14. Remove front drive unit LH mount from front drive unit. See Mount Assembly - Front Drive Unit - LH (3DU) (Remove and Replace).
  15. Disconnect the front drive unit inverter logic connector.
  16. Attach an Electrostatic Discharge (ESD) wrist strap to the front drive unit inverter housing.
  17. Remove the label from the phase out cover and discard it.
  18. Remove the bolts (x2) that attach the phase out cover to the front drive unit.
    Tip: Use of the following tool(s) is recommended:
    • 2 in extension
    • External Torx Plus EP10
    • Cordless Ratchet/Impact Driver
  19. Use a plastic trim tool to remove the phase out cover from the vehicle.
  20. Remove the bolts (x3) that attach the front drive unit inverter to the phase out terminals.
    Tip: Use of the following tool(s) is recommended:
    • 2 in extension
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  21. Remove the bolts (x12) that attach the front drive unit inverter to the gearbox.
    Tip: Use of the following tool(s) is recommended:
    • 4 in extension
    • External Torx Plus EP10
    • Cordless Ratchet/Impact Driver
  22. Carefully remove the inverter assembly from the front drive unit, remove the plugs, and allow the coolant to drain.
  23. Place the removed front drive unit inverter onto an ESD mat, and then remove the ESD wrist strap from the inverter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not place the inverter face down on the circuit board.
  24. Inspect the front drive unit gearbox housing to make sure that there is no gap pad stuck there. If there is, remove the gap pad, clean the area with an alcohol wipe, and allow at least one minute to dry.

Install

  1. Secure the ESD strap to the new inverter housing.
  2. Inspect the condition of the gap pad on the inverter PCB. Replace the gap pad if it does not fulfill these criteria:
    • New and undamaged condition.
    • Fully covers the discharge resistor array and no resistors are visible.
    • Clean and free of debris.
    • Evenly adhered to the inverter PCB.
  3. Use an IPA wipe to clean the HV mating surfaces of the front drive unit motor and front drive unit inverter phase out terminals.
  4. Install a new front drive unit inverter gasket onto the inverter.
  5. Carefully align the front drive unit inverter to the 2 pins in the front drive unit, and then install the inverter onto the drive unit. Make sure that the phase out terminals align during installation.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid damage to the printed circuit board of the inverter.
  6. Install and hand-tighten the bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox.
  7. Torque the bolts (x12) in the sequence shown.
    12.5 Nm (9.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 4 in extension
    • External Torx Plus EP10
    • Cordless Ratchet/Impact Driver
  8. Install and hand-tighten the bolts (x3) that attach the front drive unit phase out terminals to the front drive unit inverter phase out terminals.
  9. Tighten the bolts (x3) that attach the front drive unit motor phase out terminals to the front drive unit inverter phase out terminals.
    11.5 Nm (8.5 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 2 in extension
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  10. Lightly lubricate the front drive unit gearbox phase out cover bores with KAF 1 gearbox fluid, and if a new phase out cover is to be installed, lightly lubricate the O-rings of the cover.
  11. Install the phase out cover into the front drive unit gearbox, and then install the bolts (x2) that attach the cover to the gearbox.
    14 Nm (10.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 2 in extension
    • External Torx Plus EP10
    • Ratchet/torque wrench
    • ¼ in to 3/8 in adapter
  12. Apply a new front drive unit inverter phase out cover label.
  13. Attach the ESD wrist strap to the old inverter, place the old inverter into the ESD return box, and then remove the ESD wrist strap from the old inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Label and MRB the old inverter.
  14. Perform the inverter air leak test. See Inverter Air Leak Test (Inspection).
  15. Connect the front drive unit inverter logic connector.
  16. Install front drive unit LH mount to front drive unit. See Mount Assembly - Front Drive Unit - LH (3DU) (Remove and Replace).
  17. Connect PT return tube to FDU inverter inlet hose.
  18. Connect FDU PT return hose to FDU heat exchanger.
  19. Install bolt securing FDU ground strap to FDU.
    6 Nm (4.4 lbs-ft)
  20. Connect FDU HV harness connector.
  21. Install bolt securing FDU HV harness to FDU.
    10 Nm (7.4 lbs-ft)
  22. Install the front drive unit inlet hose. See Hose - Inlet - Front Drive Unit Inverter (Remove and Replace).
  23. Install the inverter to oil cooler hose. See Hose - Front Drive Unit to Oil Cooler (Remove and Replace).
  24. Install the front drive unit mount. See Mount Assembly - Front Drive Unit - LH (3DU) (Remove and Replace).
  25. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
  26. Remove the steering wheel lock from the steering wheel.
  27. On the touchscreen, perform the following steps.
    1. Select Stop Thermal Fluid Fill/Drain, select Run, then allow the routine to complete.
    2. Select Restore Bootloader Data, select Run, then allow the routine to complete.
    3. Select CAN Redeploy, select Run, then allow the routine to complete.
    4. Select Restore Application Data, select Run,then allow the routine to complete.
  28. Inspect the coolant level and top up if necessary. See Cooling System (Partial Refill and Bleed).
  29. Manually engage the hood latch.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the hood is open, or if the hood latch is not manually engaged, the vehicle speed will be limited and the resolver learn routine will fail.
  30. Press the brake pedal to ensure the drive rails are on.
  31. On the touchscreen, select Resolver Error Learn, select Run, and allow the routine to complete.
  32. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  33. Remove the stanchions from the rear of the vehicle.
  34. On the vehicle touchscreen, open the hood to disengage the hood latch.
  35. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace)..
  36. Remove the vehicle from the 2 post lift. See GUID-0ECF2493-88F6-48E9-ADBB-9AE1D52E217C.html.
  37. In this procedure, the front or rear subframe was removed and reinstalled. Therefore, refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.