23/05/2024 07:18:44

Drive Unit - Rear (4DU) (Remove and Replace)

Correction code 4001010082 FRT 3.84 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.

  • 1099645-00-C - Subframe Fixture
  • 1081765-00-A - 3/4 Ton Underhoist Stand
  • 1080568-00-A - OIL COOLANT CATCHER
  • 1135762-00-A - Coolant Hose Plug Kit
  • 1457016-00-A - SPRING COMPRESSOR, MODEL 3

Torque Specifications

Table 1. Torque Specifications: Drive Unit - Rear (4DU) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that secures the rear drive unit ground strap to vehicle
10 Nm (7.4 lbs-ft)
  • Ratchet/torque wrench
  • 10 mm 12-point deep socket
 Reuse
Bolts (x4) that attach the stiffener bracket to the subframe assembly
27 Nm (19.9 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • 13 mm deep socket
  • Flex head ratchet/flex head torque wrench
 Reuse
LH, RH and rear bolts that attach the drive unit to the subframe
80 Nm (59.0 lbs-ft)
  • Ratchet/torque wrench
  • Flex head ratchet/flex head torque wrench
  • 18 mm socket
 Reuse

Remove

  1. Verify there is no abnormal tire wear.
  2. Place the vehicle on the 2-post lift.
    Tip: Ensure the vehicle is not charging.
  3. Open all doors and lower all windows.
  4. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  5. Unlock the vehicle gateway. See Gateway Unlock.
  6. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Refrigerant System > Start Refrigerant Fill/Drain, tap Run, and allow the routine to complete.
  7. On the touchscreen, tap Controls > Service > Towing to place the vehicle into tow mode.
  8. Open the hood and the trunk lid.
  9. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  10. Remove the rear fascia. See Fascia Assembly - Rear \(Remove and Install\).
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the rear aero shield instead of partially releasing it. See Panel - Aero Shield - Rear (Remove and Replace).
  11. Remove both rear wheels. See Wheel Assembly (Remove and Install).
  12. Remove the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  13. Disconnect the LH rear EPB caliper connector.
  14. Remove and discard the bolts (x2) that attach the LH rear caliper to the LH rear knuckle, remove the caliper from the knuckle, and allow the caliper to hang from an S-hook.
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
    • Ratchet/torque wrench
  15. Install the spring compressor onto the LH rear coil spring.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tooling may vary per service center. The photos are just for reference.
  16. Remove the bolts (x2) that attach the LH rear damper to the body at the top mount.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 15 mm socket
    • 3 in extension
  17. Disconnect the LH rear damper connector, then place the harness aside for access.
  18. Repeat step 13 to 17 for the RH side.
  19. Remove the nut that secures the rear drive unit ground strap to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut is located at the LH rear wheel well area.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm 12-point deep socket
  20. Raise the vehicle to a comfortable working height, and lower the lift onto locks.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION

    Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.

    Make sure that the doors are clear of surrounding objects.

  21. Disconnect the RH side subframe harness connector
  22. Remove the RH side subframe harness clips (x2) from body.
  23. Remove the stabilizer bar assembly. See Stabilizer Bar - Rear (Remove and Replace).
  24. Release clips (x4) that secure the coolant hoses to LH and RH shear plates.
    Figure 1. LH Shown, RH Similar
  25. Remove the HV battery rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
  26. Remove the rear drive unit inverter inlet hose. See Hose - Inlet - Rear Drive Unit Inverter (Remove and Replace).
  27. Position the coolant drain container underneath the RH rear of vehicle.
  28. Release the push clips (x2) that attach the RH rear wheel liner to rocker panel, and move the wheel liner aside for access.
  29. Disconnect the rear drive unit outlet hose from the PT return tube and immediately plug both ends of fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a shop towel to clean any residue coolant if necessary. Coolant loss greater than 1L requires vacuum fill.
  30. Release the rear drive unit logic connection.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not get coolant ingress into this connector. Move the connector aside as needed.
  31. Release the rear drive unit logic connection clip.
  32. Remove the rear drive unit HV harness assembly. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
  33. Remove the rear drive unit ground strap assembly. See Ground Strap - Rear Drive Unit (Remove and Replace).
  34. Move the subframe lifting tool and the subframe away from the vehicle.
  35. Remove the bolts (x4) that attach the stiffener bracket to the subframe assembly.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 13 mm deep socket
    • Flex head ratchet/flex head torque wrench
  36. Position a fluid catcher under the subframe and fixture assembly.
  37. Remove the PT outlet hose. See Hose - Outlet - Rear Drive Unit (Remove and Replace).
  38. Remove the PT inverter to oil cooler hose. See Hose - Rear Drive Unit to Oil Coller (Remove and Replace).
  39. Pull the red tab to disengage the lock, and then pull it again to release the oil pump connector.
  40. Release the resolver connector and clips (x2), and move the harness branch aside as needed.
  41. Release the LH wheel speed sensor connector.
  42. Remove the bolt and nut that attach the LH rear upper aft link to the LH rear suspension knuckle.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm combination wrench
    • 21 mm socket
    • Flex head ratchet/flex head torque wrench
  43. Remove the bolt and nut that attach the LH rear upper fore link to the knuckle.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm combination wrench
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  44. Remove the bolt and nut that attach the LH rear toe link to the LH rear suspension knuckle.
    Tip: Use of the following tool(s) is recommended:
    • Cordless 3/8in Dr Impact
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  45. Loosen the bolt and nut that attach the LH rear lower fore link to the LH rear suspension knuckle to allow further pivoting, but do not remove the fasteners.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Cordless 3/8in Dr Impact
    • 18 mm deep socket
    • 3 in extension
    • Flex head ratchet/flex head torque wrench
  46. Separate the LH half shaft from the rear drive unit by using the cable removal kit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand-tighten the U-bolt and 2 nuts. Wrap the cable around the inner joint, and then tighten with the U-bolt. Use slide hammer with cable eyelets to release. To avoid damage to the halfshaft boots and oil seals, take special caution when removing. Remove the cable when done.
  47. Repeat step 41 to step 46 for the RH side.
  48. Position the rear subframe assembly under the gantry.
  49. Attach the 3 hooks of the drive unit sling tool to the drive unit.
  50. Secure the drive unit sling to the gantry, and raise the sling until there is slight tension on the cables.
  51. Remove the LH, RH,and rear bolts that attach the drive unit to the subframe.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
    Figure 2. LH Shown, RH Similar
    Figure 3. Rear Bolt
  52. Carefully raise the sling to lift the drive unit out of subframe. As the rear drive unit is lifted, maneuver the half shafts out of the way.
  53. Move the subframe and lifting tool from underneath the drive unit.
  54. Position an empty drive unit crate below the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pallet if no empty crate is available.
  55. Lower the drive unit into the drive unit crate.
  56. Remove the drive unit sling from the gantry and the drive unit.

Install

  1. Attach the 3 hooks of the drive unit sling tool to the drive unit.
  2. Secure the drive unit sling to the gantry.
  3. Raise the drive unit out of the drive unit crate.
  4. Move the subframe and lifting tool underneath the drive unit.
  5. Carefully lower the rear drive unit into the rear subframe. As the rear drive unit is lowered, maneuver the half shafts into the drive unit for later installation.
  6. Hand-tighten the LH, RH and rear bolts that attach the drive unit to subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at a later step.
    Figure 4. LH Shown, RH Similar
    Figure 5. Rear Bolt
  7. Lower the sling to release the tension on the cables.
  8. Hand-tighten the LH, RH and rear bolts that attach the drive unit to subframe.
    80 Nm (59.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
  9. Release the drive unit sling tool from the rear drive unit.
  10. Move the subframe assembly away from under the gantry.
  11. With assistance, position and align the LH half shaft axle splines into the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take time to make sure they are seated together correctly. Do not force them together in a way they are not meant to mate. Lift up on LH knuckle as needed.
  12. Straighten out the knuckle and the half shaft assembly, and apply shifting force to fully seat the LH rear half shaft into the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the half shaft is fully seated. Do not apply an excessive amount force. If the half shaft is not seating, check if the splines are properly aligned and if the assembly is leveled straight.
  13. Position the LH rear toe link onto the knuckle, and then install and hand-tighten the bolt and nut.
    Tip: Recommend assistance when performing this step.
  14. Install the LH rear upper fore link to the knuckle and hand-tighten the nut and bolt.
  15. Position the LH rear upper aft link onto the knuckle, and then install and hand-tighten the bolt and nut.
  16. Install the LH wheel speed sensor connector.
  17. Repeat step 11 to step 16 for the RH side.
  18. Secure the resolver connector and the clips (x2).
  19. Secure the oil pump connector.
  20. Install the PT inverter to oil cooler hose. See Hose - Rear Drive Unit to Oil Coller (Remove and Replace).
  21. Install the PT outlet hose. See Hose - Outlet - Rear Drive Unit (Remove and Replace).
  22. Install the bolts (x4) that attach the stiffener bracket to the subframe assembly.
    27 Nm (19.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 13 mm deep socket
    • Flex head ratchet/flex head torque wrench
  23. Position the subframe and the rear drive unit assembly under the vehicle.
  24. Connect the air supply to the subframe lifting tool.
  25. Install the rear drive unit ground strap assembly. See Ground Strap - Rear Drive Unit (Remove and Replace).
  26. Install the rear drive unit HV harness assembly. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Back to current procedure after installing the bolt that attaches the HV battery to rear drive unit harness bracket to the rear drive unit inverter.
  27. Verify there is no coolant ingress in the rear drive unit logic connector, and then secure the connector.
  28. Secure the rear drive unit logic connection clip.
  29. Position the coolant drain container underneath the LH rear of HV battery.
  30. Install the rear drive unit inverter inlet hose. See Hose - Inlet - Rear Drive Unit Inverter (Remove and Replace).
  31. Position the coolant drain container underneath the RH rear of vehicle.
  32. Remove the plugs on the ends of fittings, and then install the rear drive unit outlet hose to the PT return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured. Clean excess coolant from area.
  33. Secure the push clips (x2) that attach the RH rear wheel liner to the rocker panel.
  34. Remove the coolant drain container from underneath the vehicle.
  35. Install the HV battery rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
  36. Install the clips (x4) that attach the coolant hoses to the LH and RH shear plates.
    Figure 6. LH Shown, RH Similar
  37. Install the stabilizer bar assembly. See Stabilizer Bar - Rear (Remove and Replace).
  38. Install the RH side subframe harness clips (x2) to body.
  39. Connect the RH side subframe harness connector.
  40. Lower the vehicle to a comfortable working height and set the lift onto locks.
  41. Install the nut that secures the rear drive unit ground strap to vehicle.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut is located at the LH rear wheel well area. If equipped, re-install the washer as well.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm 12-point deep socket
  42. Install the bolts (x2) that attach the LH rear damper to the body at the top mount.
    41 Nm (30.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply pressure at top of the damper to push down and clear LH rear wheel arch liner.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 15 mm socket
    • 3 in extension
  43. Install the LH rear damper connector.
  44. Install new bolts (x2) that attach the LH rear caliper to the LH rear knuckle.
    83 Nm (61.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
    • Ratchet/torque wrench
  45. Connect the LH rear EPB caliper connector.
  46. Remove the bolt that attaches the LH rear rotor to hub.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
  47. Install the hub jack adapter onto the LH rear hub and hand-tighten the lug nuts (x5).
  48. Position and raise the support stand to simulate the LH rear suspension at ride height.
  49. Use the rear ride height torque gauge to verify that the LH suspension is set to ride height specification.
  50. Measure from the bottom of quarter panel to the center of axle as a secondary check to make sure the LH suspension is set to ride height. The distance should be 378 mm.
  51. Tighten the bolt and nut that attach the LH rear upper aft link to the knuckle, and then mark the bolt and nut with a paint pen.
    134 Nm (98.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm combination wrench
    • 21 mm socket
    • Flex head ratchet/flex head torque wrench
  52. Tighten the bolt and nut that attach the LH rear upper fore link to the knuckle, and then mark the bolt and nut with a paint pen.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm combination wrench
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  53. Tighten the bolt and nut that attach the LH rear toe link to the LH rear suspension knuckle. Mark the bolt with a paint pen.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Cordless 3/8in Dr Impact
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  54. Tighten the bolt and nut that attach the LH rear lower fore link to the knuckle, and then mark the bolt and nut with a paint pen.
    76 Nm (56.0 lbs-ft)
  55. Remove the support stand from underneath the LH rear suspension.
  56. Remove the hub jack adapter from the LH rear hub.
  57. Install the bolt that attaches the LH rear rotor to hub.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
  58. Remove the spring compressor from the LH rear coil spring.
  59. Repeat step 42 to step 58 for the RH side.
  60. Lower the vehicle to a comfortable working height and set the lift onto locks.
  61. Install the rear fascia. See Fascia Assembly - Rear \(Remove and Install\).
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully install the rear aero shield. See Panel - Aero Shield - Rear (Remove and Replace).
  62. Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  63. Install both rear wheels. See Wheel Assembly (Remove and Install).
  64. Install the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  65. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
  66. Connect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
  67. Connect an LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  68. Unlock the vehicle gateway. See Gateway Unlock.
  69. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Refrigerant System > Stop Thermal Fill Drain, and then allow the routine to complete.
  70. Reinstall the vehicle firmware. See Software Reinstall - Touchscreen.
  71. Hold the brake pedal and select park on UI to disable the EPB service mode.
  72. Disconnect the LV maintainer.
  73. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Purge Start, click Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  74. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  75. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions, then click the START button next to Test Thermal Performance, click Run, and allow the routine to complete.
  76. Select the START button next to Test HVAC Performance, click Run, and then allow the routine to complete.
  77. Install the cabin intake duct. See Assembly - Fresh Air Gutter - HVAC (Remove and Replace).
  78. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  79. Close the hood and the trunk lid.
  80. Move both front seats to original position.
  81. Disable Service Mode. See Service Mode.
  82. Raise all windows and close all doors.
  83. Remove the lift arms from below the vehicle.
  84. Review wheel alignment requirements and add correction code as needed.