04/12/2024 09:11:26

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

Correction code 40200612 2.76 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.
  • 2024-02-27: Updated gearbox fluid to KAF 1.
  • 2023-07-25: Removed resolver error learn substeps.
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. While performing the courtesy inspection, note any abnormal tire wear that could indicate the need for an alignment.
  2. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  3. Place stanchions around the rear of the vehicle to setup a safety perimeter.
  4. Verify that the vehicle firmware is version 2022.20.6 or later. Update the vehicle firmware if this is not the case. See Software Update.
  5. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  6. In Toolbox 3, click the Dashboards tab, and type ‘Rear Drive Inverter Replacement' into the search field, and click [Model 3/Y] REAR Drive INVERTER - Replacement.
  7. From the BEFORE INVERTER SWAP Action List, click Store Drive Inverter Bootloader Data before Replacement, click Run, and allow the routine to complete.
  8. From the BEFORE INVERTER SWAP Action List, click Store Drive Inverter Application Data before Replacement, click Run, and allow the routine to complete.
  9. From the BEFORE INVERTER SWAP Action List, click Start Thermal Fluid Fill/Drain (Coolant only), click Run, and allow the routine to complete.
  10. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not close this instance of Toolbox 3 as it is needed later on in the procedure.
  11. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  12. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  13. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  14. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  15. Remove the LH and RH rear wheels. See Wheel (Remove and Replace).
  16. Remove the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  17. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  18. Remove the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  19. Disconnect the electrical harness from the rear subframe harness RH connector.
  20. Release the clip that attaches the rear subframe harness to the body on the RH side.
  21. Disconnect the electrical harness from the rear subframe harness LH connector.
  22. Release the clip that attaches the rear subframe harness to the body on the LH side.
  23. Remove the nut that attaches the rear drive unit ground strap to the body in the LH rear wheel arch, and then remove the ground strap from the body.
  24. Remove and discard the nut that attaches the LH rear stabilizer bar end link to the rear stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
  25. Remove LH rear stabilizer bar end link from the rear stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the stabilizer bar up and down to ease removal of the end link.
  26. Remove and discard the nut that attaches the RH rear stabilizer bar end link to the rear stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
  27. Remove RH rear stabilizer bar end link from the rear stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the stabilizer bar up and down to ease removal of the end link.
  28. Remove and discard the bolts (x4) that attach the rear stabilizer bar to the rear subframe, and then remove the stabilizer bar from the subframe.
  29. Release the clips (x2) that attach the coolant hoses to LH shear plate.
  30. Release the clips (x4) that secure coolant hoses to the rear skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clip quantity varies with older vehicles.
  31. Release the clips (x2) that attach the coolant hoses to RH shear plate.
  32. Remove the HV battery rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  33. Position a coolant drain collector underneath the LH rear of the HV battery.
  34. Release the clip, disconnect the rear drive unit inverter inlet hose from the HV battery, and then immediately plug both fittings.
  35. Release the clip, disconnect the rear drive unit inverter inlet hose from the rear drive unit inverter, and then immediately plug both fittings.
  36. Release the clip that attaches the rear drive unit inverter inlet tube from rear drive unit HV harness.
  37. Remove the rear drive unit inverter inlet tube down and out from between the rear subframe and the HV battery.
  38. Remove the coolant drain collector from under the vehicle.
  39. Release the locking tab, push the handle downward, and then disconnect the rear subframe electrical harness from the rear drive unit inverter logic connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Once disconnected, make sure that coolant does not get into the connectors.
  40. Release the clip that attaches the rear subframe electrical harness to the rear drive unit inverter.
  41. Remove the bolt that attaches the rear drive unit HV harness bracket to the rear drive unit inverter.
  42. Slide the locking tab, raise the black handle, disconnect the rear drive unit HV harness from the rear drive unit inverter HV header,and then set the HV harness aside.
  43. Remove the nut(s) that attach(es) the rear drive unit HV harness bracket to the HV battery.
  44. Slide the red locking tab, raise the black handle, and then disconnect the rear drive unit HV harness from the HV battery header.
  45. Remove the rear drive unit HV harness down and out from between the rear subframe and the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the harness as it is removed to allow access for the bracket.
  46. Position the subframe lifting tool under, and up against the rear subframe.
  47. With the help of an assistant, fully secure the straps (x3) that attach the rear subframe to the subframe lifting tool.
  48. Use a paint pen to trace around the LH and RH rear subframe mounting bolts, so that the bolts can be realigned later during the subframe installation.
  49. Use a paint pen to apply a witness mark where the rear subframe contacts the body at the LH and RH rear subframe mounting bolts, so that the subframe can be realigned to the body later during subframe installation.
  50. Remove the small bolts (x2) that attach the LH shear plate to the HV battery.
  51. Remove the large bolt that attaches the LH shear plate and rear subframe to the body, and then remove shear plate.
  52. Remove the small bolts (x2) that attach the RH shear plate to the HV battery.
  53. Remove the large bolt that attaches the RH shear plate and rear subframe to the body, and then remove shear plate.
  54. Remove and discard the LH rear subframe bolt that attaches the subframe to the body.
  55. Remove and discard the RH rear subframe bolt that attaches the subframe to the body.
  56. Carefully lower the subframe and rear drive unit assembly approximately 8.25 cm (3.25 in) from the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not lower the subframe any more than 8.25 cm (3.25 in) as suspension and brake components are still attached to both the subframe and the body.
  57. Tilt the subframe fixture forward in order to access motor mount fasteners.
  58. Insert a rubber or wood block between the rear drive unit and the subframe fixture so as to support the rear drive unit while the LH mount is removed.
  59. Release the clip that attaches the rear drive unit ground strap to the rear subframe.
  60. Release the clips (x2) that attach the rear drive unit inverter to heat exchanger hose to the rear drive unit.
  61. Remove the LH mount bolt that attaches the rear drive unit LH mount to the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pry bar between the block and rear drive unit to unload the bolt so that it can be removed.
  62. Remove and discard the bolts (x3) that attach the rear drive unit LH mount to the rear drive unit.
  63. Release the clip, disconnect the rear drive unit inverter to heat exchanger hose from the rear drive unit inverter outlet, and then immediately plug both fittings.
  64. Remove the rear drive unit LH mount up, over, and out between the rear subframe and the body.
  65. Rotate the clip counter-clockwise to release, and then remove the NVH cover from the rear drive unit.
  66. Put on the ESD wrist strap and attach it to the rear drive unit inverter housing.
  67. Remove and discard the rear drive unit phase out cover label to access the bolts behind.
  68. Remove the bolts (x2) that attach the phase out cover to the rear drive unit gearbox, and then use a plastic trim tool to remove the cover from the gearbox.
  69. 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-C or newer revision, for installation.
  70. Remove the bolts (x3) that attach the rear drive unit motor 3-phase terminals to the rear drive unit LH inverter 3-phase terminals.
  71. Remove the bolts (x9) that attach the rear drive unit inverter to the rear drive unit gearbox..
  72. 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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the inverter circuit board when removing the inverter.
  73. Remove the plugs from the inverter and drain the coolant.
  74. Set the rear drive unit inverter onto an ESD mat, and then remove the ESD wrist strap clip from the inverter housing.
  75. Inspect the rear 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Also inspect the gearbox housing and remove any dropped fasteners or loose debris.

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. Use and IPA wipe to clean mating surface of the rear drive unit gearbox, and allow at least one minute to dry.
  4. 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.
  5. Install and hand-tighten the bolts (x9) that attach the new rear drive unit inverter to the rear drive unit LH gearbox.
  6. 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.
    12.5 Nm (9.2 lbs-ft)
  7. Install and hand-tighten the bolts (x3) that attach the rear drive unit motor 3-phase terminals to the new rear drive unit inverter 3-phase terminals.
  8. Tighten the bolts (x3) that attach the rear drive unit motor 3-phase terminals to the new rear drive unit inverter 3-phase terminals.
    11.5 Nm (8.5 lbs-ft)
    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
    If installing a new bolt, tighten to 12.5 Nm, back off 180 degrees, then torque to 5 Nm +40 degrees.
  9. 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.
  10. 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)
  11. Install a new phase out cover label.
  12. Remove the ESD wrist strap from the new inverter, attach it to the old inverter, and prepare the old inverter for shipment to MRB.
  13. Perform an inverter air leak test. See Inverter Air Leak Test.
  14. Install the NVH cover onto the rear drive unit, and then rotate the clip clockwise to fasten.
  15. Install the rear drive unit LH mount in, over, and down between the rear subframe and the body.
  16. Remove the plugs from the fittings, immediately connect the rear drive unit inverter to heat exchanger hose to the rear drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  17. Install the rear drive unit LH mount to the rear drive unit, and then install and hand-tighten new bolts (x3) to attach the mount to the drive unit.
  18. Tighten the bolts (x3) that attach the rear drive unit LH mount to the rear drive unit in the sequence shown.
    35 Nm (25.8 lbs-ft) +55 deg
  19. Install the LH mount bolt that attaches the rear drive unit LH mount to the rear subframe.
    80 Nm (59.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pry bar between the block and rear drive unit to position the mount so that the bolt can be installed.
  20. Fasten the clips (x2) that attach the rear drive unit inverter to heat exchanger hose to the rear drive unit.
  21. Fasten the clip that attaches the rear drive unit ground strap to the rear subframe.
  22. Remove the block from between the rear drive unit and the subframe fixture.
  23. Tilt the subframe fixture backward to its original position.
  24. Carefully raise the subframe and rear drive unit assembly until they are up against the body.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be mindful of the suspension and brake components that are still attached to both the subframe and the body.
  25. Install and hand-tighten a new RH rear subframe bolt to attach the rear subframe to the body.
  26. Install and hand-tighten a new LH rear subframe bolt to attach the rear subframe to the body.
  27. Install the RH shear plate to the rear subframe, and then install a new large bolt to attach the RH shear plate and rear subframe to the body.
  28. Install and hand-tighten the small bolts (x2) that attach the RH shear plate to the HV battery.
  29. Install the LH shear plate to the rear subframe, and then install a new large bolt to attach the LH shear plate and rear subframe to the body.
  30. Install and hand-tighten the small bolts (x2) that attach the LH shear plate to the HV battery.
  31. Use a pry bar to shimmy the rear subframe with respect to the body, so that the subframe mounting bolts are centered in the tracings, and the witness marks align where the subframe contacts the body.
  32. Tighten the RH rear subframe bolt that attaches the rear subframe to the body, and then mark the bolt after tightening.
    165 Nm (121.7 lbs-ft)
  33. Tighten the LH rear subframe bolt that attaches the rear subframe to the body, and then mark the bolt after tightening.
    165 Nm (121.7 lbs-ft)
  34. Tighten large bolt that attaches the LH shear plate and rear subframe to the body, and then mark the bolt after tightening.
    130 Nm (95.9 lbs-ft)
  35. Tighten large bolt that attaches the RH shear plate and rear subframe to the body, and then mark the bolt after tightening.
    130 Nm (95.9 lbs-ft)
  36. Tighten the small bolts (x2) that attach the RH shear plate to the HV battery.
    35 Nm (25.8 lbs-ft)
  37. Tighten the small bolts (x2) that attach the LH shear plate to the HV battery.
    35 Nm (25.8 lbs-ft)
  38. Release the straps (x3) that attach the rear subframe to the subframe lifting tool.
  39. Lower the subframe lifting tool, and move it out from under the vehicle.
  40. Install the rear drive unit HV harness in and up between the rear subframe and the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the harness as it is installed to allow access for the bracket.
  41. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery header, secure the release lever to the closed position, and then slide the red connector locking tab.
  42. Install the nut(s) that attach(es) the rear drive unit HV harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
  43. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the rear drive unit inverter HV header, secure the release lever to the closed position, and then slide the connector locking tab.
  44. Install the bolt that attaches the rear drive unit HV harness bracket to the rear drive unit inverter.
    6 Nm (4.4 lbs-ft)
  45. Inspect the rear subframe electrical harness logic connector and the rear drive unit inverter logic connector for coolant, and use shop air and a clean dry shop towel to remove any coolant from the connectors.
  46. Connect the rear subframe electrical harness to the rear drive unit inverter logic connector, raise the handle upward, and fasten the locking tab.
  47. Fasten the clip that attaches the rear subframe electrical harness to the rear drive unit inverter.
  48. Position a coolant drain collector underneath the LH rear of the HV battery.
  49. Install the rear drive unit inverter inlet tube in and up between the rear subframe and the HV battery.
  50. Fasten the clip that attaches the rear drive unit inverter inlet tube to rear drive unit HV harness.
  51. Remove the plugs from the fittings, immediately connect the rear drive unit inverter inlet hose to the rear drive unit inverter, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  52. Remove the plugs from the fittings, immediately connect the rear drive unit inverter inlet hose to the HV battery, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  53. Remove the coolant drain collector from under the vehicle.
  54. Install the HV battery rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  55. Fasten the clips (x2) that attach the coolant hoses to RH shear plate.
  56. Fasten the clips (x4) that secure coolant hoses to the rear skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clip quantity varies with older vehicles.
  57. Fasten the clips (x2) that attach the coolant hoses to LH shear plate.
  58. Install the rear stabilizer bar to the rear subframe, and then install new bolts (x4) to attach the stabilizer bar to the subframe.
    30 Nm (22.1 lbs-ft)
  59. Install the LH rear stabilizer bar end link into the rear stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the stabilizer bar up and down to ease installation of the end link.
  60. Install a new nut to attach the LH rear stabilizer bar end link to the rear stabilizer bar.
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
  61. Install the RH rear stabilizer bar end link into the rear stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the stabilizer bar up and down to ease installation of the end link.
  62. Install a new nut to attach the RH rear stabilizer bar end link to the rear stabilizer bar.
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
  63. Install the rear drive unit ground strap to the body in the LH rear wheel arch, and then install the nut that attaches the ground strap to the body.
    10 Nm (7.4 lbs-ft)
  64. Fasten the clip that attaches the rear subframe harness to the body on the LH side.
  65. Connect electrical harness to the rear subframe harness LH connector.
  66. Fasten the clip that attaches the rear subframe harness to the body on the RH side.
  67. Connect electrical harness to the rear subframe harness RH connector.
  68. Install the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  69. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  70. Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  71. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  72. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  73. Connect an LV maintainer to the vehicle, and then disconnect the LV battery. See LV Maintainer (Connect and Disconnect).
  74. Reconnect the laptop with Toolbox 3 to the vehicle.
  75. In Toolbox 3, click the Dashboards tab, and type ‘Rear Drive Inverter Replacement' into the search field, and click [Model 3/Y] REAR Drive INVERTER - Replacement.
  76. From the AFTER INVERTER SWAP Action List, click Stop Thermal Fluid Fill/Drain, click Run, and allow the routine to complete.
  77. From the AFTER INVERTER SWAP Action List, click Restore REAR Drive INVERTER Bootloader Data after Replacement and Usage ID Configuration, click Run, and allow the routine to complete.
  78. From the AFTER INVERTER SWAP Action List, click Service CAN Redeploy, click Run, and allow the update to finish.
  79. Reconnect the LV battery, and then disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  80. From the AFTER INVERTER SWAP Action List, click Restore Drive Inverter Application Data after Replacement, click Run, and allow the routine to complete.
  81. From the AFTER INVERTER SWAP Action List, click Secure pairing (immobilizer pairing) between the Security Controller and Drive Inverter and Vehicle Odometer Pairing to UI, click Run, and allow the routine to complete.
  82. From the AFTER INVERTER SWAP Action List, click Coolant Air Purge, click Run, and allow the routine to complete.
  83. From the AFTER INVERTER SWAP Action List, click Thermal System Performance Test, click Run, and allow the routine to complete.
  84. Add coolant to the reservoir as necessary, and install the reservoir cap.
  85. 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.
  86. Touch the brake pedal to ensure the drive rails are on.
  87. From the RESOLVER LEARN Action List, click Rear Drive Unit Resolver Error Learning, click Run, and follow the displayed instructions.
  88. Disconnect the laptop with Toolbox 3 from the vehicle.
  89. Install the LH and RH rear wheels. See Wheel (Remove and Replace).
  90. Remove the stanchions from the rear of the vehicle.
  91. On the vehicle touchscreen, open the hood to disengage the hood latch.
  92. Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  93. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  94. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  95. Perform a validation test drive at road and highway speeds to determine if an alignment check is necessary.
    • If the test drive shows the vehicle to track poorly or pull to the side, or if steering is sloppy or off center, then perform a four wheel alignment check. See Four Wheel Alignment Check, and add this service to the SV.
    • If the test drive shows the vehicle to steer and handle as expected, then an alignment check is not necessary.