04/12/2024 10:16:59

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

Correction code 4001020132 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.

  • 2024-12-04: Updated inverter fastener torque sequence.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Inspect the vehicle for abnormal tire wear that might indicate the need for a wheel alignment. Note any findings.
  2. Raise and support the vehicle. See GUID-0ECF2493-88F6-48E9-ADBB-9AE1D52E217C.html.
  3. Open all doors and lower all windows.
  4. 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.
  5. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap High Voltage > Procedures > Rear Drive Inverter Replacement > Store Bootloader Data, tap Run, and allow the routine to complete.
  6. Tap Store Application Data, tap Run, and allow the routine to complete.
  7. Tap Start Fluid Fill/Drain, tap Run, and allow the routine to complete.
  8. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  9. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  10. Disconnect LV power. See LV Battery - Li-lon (Disconnect and Connect).
  11. Remove the fresh air gutter. See Assembly - Fresh Air Gutter - HVAC (Remove and Replace).
  12. Remove the 2nd row lower seat cushion, See Seat Cushion - 2nd Row (Remove and Replace).
  13. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  14. Remove the rear wheels. See Wheel Assembly (Remove and Install).
  15. Remove the rear aero shield panel, See Panel - Aero Shield - Rear (Remove and Replace).
  16. Remove the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  17. Remove the rear fascia assembly. See Fascia Assembly - Rear \(Remove and Install\).
  18. Remove the nut that attaches the rear drive unit ground strap to the body.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
    • Ratchet/torque wrench
  19. Disconnect the RH subframe harness electrical connector.
  20. Remove the RH side subframe harness clips (x2) from body.
  21. Remove and discard the nuts (x2) that attach the stabilizer bar to the end links, and then remove the stabilizer bar from the end links.
    Informational PurposesAn informational icon, calling your attention
    Note
    Loosen the nut first, and then continue to remove the nut by counter-holding the ball joint with a hex wrench.
    Informational PurposesAn informational icon, calling your attention
    Note
    Might need to move the rear stabilizer bar up/down to get the correct angle in order to remove the end links.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
  22. Release clips (x4) that secure the coolant hoses to LH and RH shear plates.
    Figure 1. LH Shown, RH Similar
  23. Remove the HV battery rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
  24. Remove the rear drive unit inverter inlet hose. See Hose - Inlet - Rear Drive Unit Inverter (Remove and Replace).
  25. 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.
  26. Release the rear drive unit logic connection clip.
  27. Remove the rear drive unit HV harness assembly. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
  28. Remove the rear drive unit mount. See Mount - Rear Drive Unit - LH (4DU) (Remove and Replace).
  29. Rotate the clip counter-clockwise to release, and then remove the NVH cover from the rear drive unit.
  30. Put on ESD wrist strap and secure it to inverter housing.
  31. Remove and discard the label from phase cover.
  32. Remove the bolts (x2) that attach the rear drive unit phase out cover to the rear drive unit gearbox, and then use a plastic trim tool to remove the cover from the gearbox.
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  33. Inspect the condition of the phase out cover and O-rings. If the cover has less than 6 O-rings, or if the O-rings or cover are damaged, discard the cover and use a new cover, part 1096984-00-E or newer revision, for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to aid in removal. If the phase out cover or O-rings are damaged then replace with a new one.
  34. Remove and discard the bolts (x3) that attach the rear drive unit motor 3-phase terminals to the rear drive unit LH inverter 3-phase terminals.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  35. Remove and discard the bolts (x9) that attach the rear drive unit inverter to the gearbox assembly.
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  36. Carefully remove the rear drive unit inverter from the rear drive unit gearbox, and move the inverter down and out between the rear subframe and drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take care not to damage the inverter circuit board when removing the inverter.
  37. Remove the plugs from the inverter and drain the coolant.
  38. Set the rear drive unit inverter onto an ESD mat, and then remove the ESD wrist strap clip from the inverter housing.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not place inverter facing downwards on the circuit board as it is fragile.

Install

  1. Prepare the new rear drive unit inverter and attach the ESD strap to the new inverter housing
  2. Use an IPA wipe to clean the phase terminals of the rear drive unit motor and the new rear drive unit inverter, and allow at least one minute to dry.
  3. Carefully install the new rear drive unit inverter in and up between the rear subframe and rear drive unit. Align the inverter to the 2 pins in the rear drive unit gearbox, and then install the inverter to the gearbox.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the inverter circuit board when installing the inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the phase terminals align during installation.
  4. Install and hand-tighten new bolts (x9) (1100020-00-A or newer) that attach the new rear drive unit inverter to the rear drive unit LH gearbox.
  5. Tighten the 2 bolts nearest the alignment dowels first, and then tighten the remaining bolts (x7) that attach the new rear drive unit inverter to the rear drive unit gearbox.
    6 Nm (4.4 lbs-ft) + 20 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  6. Install and hand-tighten new bolts (x3) (112246-00-A or newer) that attach the rear drive unit motor 3-phase terminals to the new rear drive unit inverter 3-phase terminals.
  7. Tighten the bolts (x3) that attach the rear drive unit motor 3-phase terminals to the new rear drive unit inverter 3-phase terminals.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If any bolts are dropped into the gearbox housing, they must be retrieved.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten to 12.5 Nm, back off 180 degrees, then torque to 5 Nm + 40 degrees.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  8. Lightly lubricate the rear drive unit gearbox phase out cover bores with KAF 1 fluid, and if a new phase out cover is to be installed, lightly lubricate the O-rings of the cover.
  9. Install the phase out cover into the rear 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:
    • External Torx Plus EP10
  10. Install a new phase out cover label.
  11. Remove the ESD wrist strap from the inverter.
  12. Perform an inverter air leak test. See Inverter Air Leak Test (Inspection).
  13. Install the NVH cover onto the rear drive unit, and then rotate the clip clockwise to fasten.
  14. Install the rear drive unit mount. See Mount - Rear Drive Unit - LH (4DU) (Remove and Replace).
  15. Install the rear drive unit HV harness assembly. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
  16. Verify there is no coolant ingress in the rear drive unit logic connector, and then secure the connector.
  17. Secure the rear drive unit logic connection clip.
  18. Position the coolant drain container underneath the LH rear of HV battery.
  19. Install the rear drive unit inverter inlet hose. See Hose - Inlet - Rear Drive Unit Inverter (Remove and Replace).
  20. Install the high voltage skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  21. Install the clips (x4) that attach the coolant hoses to the LH and RH shear plates.
  22. Align the LH and RH end links with the rear stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the rear stabilizer bar up/down to get the correct angle to install the rear link.
  23. Install new nuts that attaches the stabilizer bar to the LH and RH end links. Mark the nut with a paint pen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Counter-hold the ball joint with a hex wrench.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
  24. Install the RH side subframe harness clips (x2) to body.
  25. Connect the RH side subframe harness connector.
  26. Lower the vehicle to a comfortable working height and set the lift onto locks.
  27. 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
  28. Install the rear fascia assembly. See Fascia Assembly - Rear \(Remove and Install\).
  29. Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  30. Remove the rear aero shield panel, See Panel - Aero Shield - Rear (Remove and Replace).
  31. Install the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  32. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
  33. Connect the first responder loop and leave LV battery disconnected.
  34. Connect the LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  35. 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.
  36. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap High Voltage > Procedures > Rear Drive Inverter Replacement > Stop Fluid Fill/Drain, tap Run, and allow the routine to complete.
  37. Tap Restore Bootloader Data, tap Run, and allow the routine to complete.
  38. Tap CAN Redeploy, tap Run, and allow the routine to complete.
  39. Tap Restore Application Data, tap Run, and allow the routine to complete.
  40. Tap Coolant Air Purge, tap Run, and allow the routine to complete.
  41. Disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  42. Connect LV battery.
  43. Tap Thermal system Test, tap Run, and allow the routine to complete.
  44. 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.
  45. Manually engage the hood latch.
    Informational PurposesAn informational icon, calling your attention
    Note
    Manually engage hood latch for resolver error learn.
  46. Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use safety stanchions to section off vehicle before driving vehicle on a lift.
  47. Press the brake pedal to turn on drive rails.
  48. Tap Resolver Error Learn, tap Run, and allow the routine to complete.
  49. Disable Service Mode. See Service Mode.
  50. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  51. Install rear wheels. See Wheel Assembly (Remove and Install).
  52. Remove safety stanchions from around vehicle after resolver learn is completed.
  53. Install the fresh air gutter. See Assembly - Fresh Air Gutter - HVAC (Remove and Replace).
  54. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  55. Raise all windows and close all doors.
  56. Remove the vehicle from the lift.
  57. Review wheel alignment requirements and add correction code as needed.