06/05/2024 18:51:49

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

Correction code 4001010052 FRT 0.72 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.

  • 1134264-00-A - Drive Unit Oil Drain Kit
  • 1541474-00-B - Oil Catch/Measure Kit

Torque Specifications

Table 1. Torque Specifications: Heat Exchanger - Rear Drive Unit (4DU) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
4DU oil fill plug
15 Nm (11.1 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 8 mm socket
  • 6 in extension
  • ¼ in to 3/8 in adapter
  • Ratchet/torque wrench
 Reuse
4DU oil drain plug
15 Nm (11.1 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 8 mm socket
 Reuse
Bolts (x2) that attach the heat exchanger to the drive unit
5 Nm (3.7 lbs-ft) + 30 degrees
  • Flex head ratchet/flex head torque wrench
  • 4 in extension
  • External Torx Plus EP10
  • Torque wrench with angle measurement
 Reuse

Remove

  1. Place the vehicle on the 2-post lift.
    Tip: Ensure the vehicle is not charging.
  2. Open the LH front door and lower the LH front window.
  3. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  4. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  5. Disconnect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
  6. Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  7. Remove the oil fill plug from the 4DU.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
    • 6 in extension
    • ¼ in to 3/8 in adapter
    • Ratchet/torque wrench
  8. Pull the red tab to disengage the lock, and then pull it again to release the oil pump connector.
  9. Position an oil drain container under the rear of vehicle.
  10. Release the oil drain plug from 4DU drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Some fluid will drain out.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  11. Connect the 12V power supply to the oil pump switchbox, and then secure the oil pump switchbox to the oil pump connector.
  12. Run the oil pump power supply for 1 minute and drain the remaining oil from the 4DU drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take precaution because the oil will shoot out at a wide angle. Adjust the position of the oil drain container as needed. Do not run oil pump dry for extended period of time.
  13. Release the power supply and the oil pump switchbox from the oil pump connector.
  14. Secure the oil pump connector.
  15. Secure the oil drain plug.
    15 Nm (11.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the O-ring is not damaged. Replace O-ring as needed.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  16. Remove the oil drain container from underneath the drive unit.
  17. Position a coolant drain container under the rear of vehicle.
  18. Release the clips (x2) that attach the inverter to oil cooler hose to the heat exchanger, and plug the ends of fittings as soon as possible to avoid coolant loss.
  19. Release the clips (x2) that attach the PT outlet hose to the heat exchanger, and plug the ends of fittings as soon as possible to avoid coolant loss.
  20. Release the bolts (x2) that attach the heat exchanger to the drive unit, and then remove the heat exchanger from the rear drive unit assembly.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 4 in extension
    • External Torx Plus EP10
    • Torque wrench with angle measurement

Install

  1. Apply a light coat of KAF1 oil to the O-rings of the heat exchanger, and then wipe away any residue.
  2. Install the rear drive unit heat exchanger onto the rear drive unit, and then install the bolts (x2) that attach the heat exchanger to the drive unit.
    5 Nm (3.7 lbs-ft) + 30 degrees
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 4 in extension
    • External Torx Plus EP10
    • Torque wrench with angle measurement
  3. Remove the plugs on the ends of fittings, then secure the clips (x2) that attach the PT outlet hose to the heat exchanger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
  4. Remove the plugs on the ends of fittings, then secure the clips (x2) that attach the inverter to oil cooler hose to the heat exchanger.
  5. Remove the coolant drain container from underneath the vehicle.
  6. Position the oil drain container under the rear of vehicle.
  7. Set up the fill kit (1541474-00-B) with KAF 1, fill the measuring container to 2500 ml.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Only use KAF1 fluid for the 4DU drive unit. Do not interchange or mix oil types.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 4DU drive unit will take 2300 ml of fluid, but add extra oil to the container as it will prevent underfill and additional air being injected.
  8. Trim both input and output hoses to 26 inches, and then insert the output hose into fill hole until it is fully seated. Then pull the hose back 5mm.
  9. Place the measured fluid container in the drain basket, fully submerge the input hose in the fluid, then prime the pump with the drive unit fluid.
  10. Pump the fluid into the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fill specification for the 4DU drive unit is 2.3L. Excess gearbox fluid in the fill container is used to allow the oil pump to dispense the full 2.3L without drawing air. Pumping the full 2.5L is not required. Make sure that there is less than 200mL left when completed.
  11. Install the oil fill plug to the 4DU drive unit.
    15 Nm (11.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the O-ring is not damaged. Replace the O-ring as needed.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
    • 6 in extension
    • ¼ in to 3/8 in adapter
    • Ratchet/torque wrench
  12. Spray the area with brake cleaner and wipe residual fluid off with towel.
  13. Remove the oil drain container from underneath the drive unit.
  14. Install the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  15. Connect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
  16. 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 then allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the coolant loss is greater than 1L, perform vacuum fill instead.
    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.
  17. 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.
  18. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Test Thermal Performance, click Run, and allow the routine to complete.
  19. Exit Service Mode. See Service Mode.
  20. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  21. Raise the LH front window and close the LH front door.
  22. Remove the lift arms from below the vehicle.