22/05/2024 15:22:59

Drive Unit - Front (Remove and Replace)

Correction code 39012102 4.02 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.

  • 2024-01-24: Added a note to install a new motor ID label in hood/trunk for China, Japan and Korea.
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. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Connect a laptop with Toolbox 3 to the vehicle.
  3. In Toolbox 3, click the Dashboards tab, and and type ‘Front Drive Unit Replacement' into the search field.
  4. Click Front Drive Unit Replacement, from the Before Front Drive Unit Replacement Action List, click Start Thermal Fluid Fill/Drain (Coolant only), click Run, and then allow the routine to complete.
  5. Disconnect the laptop with Toolbox 3 from the vehicle.
    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.
  6. Use a steering wheel lock to firmly set the steering wheel in the straight forward position.
  7. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  8. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  9. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  10. Remove the bolt that attaches the intermediate shaft to the steering gear, and then slide the intermediate shaft upwards to remove it from the steering gear.
    Figure 1. Heat Pump Model 3
    Figure 2. Model 3
  11. Disconnect the electrical harness from the front subframe electrical harness.
  12. Slide the red tab to unlock, press the connector release, and then disconnect the electrical harness from the steering gear power connectors (x2).
  13. Model 3 - Pull the grey tab to unlock, then pull the grey tab again to disconnect the electrical harness from the LV logic connectors (x2) at the steering gear.
  14. Remove the front LH and RH wheels. See Wheel Assembly (Remove and Install).
  15. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  16. Remove the front fascia. See Fascia - Front (Remove and Install).
  17. Remove the front subframe. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
  18. Move a coolant catcher under the front subframe and fixture assembly.
  19. Release the clip, disconnect the front drive unit inverter to heat exchanger hose from the front drive unit inverter outlet, plug the inverter fitting, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel to direct flow.
    Figure 3. Heat Pump Model 3
    Figure 4. Model 3
  20. Release the clip, disconnect the front drive unit inverter to heat exchanger hose from the front drive unit heat exchanger, plug the heat exchanger fitting, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel to direct flow.
    Figure 5. Heat Pump Model 3
    Figure 6. Model 3
  21. Release the clips (x2) that attach the front drive unit inverter to heat exchanger hose to the front drive unit, and then remove the hose from the front drive unit.
    Figure 7. Heat Pump Model 3
    Figure 8. Model 3
  22. Release the clip, disconnect the front drive unit inverter inlet hose from the front drive unit inverter inlet, plug the inverter fitting, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel to direct flow.
  23. Release the clips (x2) that attach the front drive unit inverter inlet hose to the front drive unit, and then remove the hose from the drive unit.
  24. Release the locking tab, push the handle downward, and then disconnect the subframe electrical harness from the front drive unit inverter logic connector.
  25. Release the clips (x2) that attach the subframe electrical harness to the inverter.
  26. Release the clip that attaches the subframe electrical harness to the front drive unit motor.
    Figure 9. Heat Pump Model 3
    Figure 10. Model 3
  27. Pull the red locking tab out of the connector, and then pull the red tab again to disconnect the subframe electrical harness from the oil pump connector.
  28. Use the halfshaft removal cable with the slide hammer to loosen the LH front halfshaft from the front drive unit, and then fold the LH knuckle outward to remove the halfshaft from the drive unit.
  29. Use the halfshaft removal cable with the slide hammer to loosen the RH front halfshaft from the front drive unit, and then fold the RH knuckle outward to remove the halfshaft from the drive unit.
  30. Move the subframe lifting tool to under the gantry.
  31. Use the shackles (x3) to attach the drive unit sling tool to the front drive unit.
  32. Attach the drive unit sling tool to the gantry.
  33. Use the gantry to raise the drive unit sling tool so that there is slight tension in the cables.
  34. Remove the bolt that attaches the front drive unit to the front of the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise or lower the drive unit sling tool to aid in removing the bolt.
  35. With the help of an assistant, use the gantry to raise the drive unit sling tool, guide halfshafts away from the front drive unit, and separate the front drive unit up from the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the front drive unit rear support posts are not moved out of their current position
  36. Move the front subframe and subframe lift out from underneath the front drive unit.
  37. Set the front drive unit down onto an appropriate surface, continue lowering to put slack into the drive sling tool cables, and then remove the shackles (x3) from the drive unit.
  38. Open the crate for the new front drive unit, remove the protective covers from the new drive unit, and transfer them to the old drive unit.

Install

Informational PurposesAn informational icon, calling your attention
Note
New front drive units come prefilled with gearbox fluid. Clean up any leaks during installation and top off the gearbox fluid as necessary.
  1. Move the gantry to the new front drive unit.
  2. Use the shackles (x3) to attach the drive unit sling tool to the new front drive unit.
  3. Use the gantry to raise the drive unit sling tool so that there is slight tension in the cables.
  4. Remove the bolts (x3) that attach the new front drive unit to the front drive unit crate.
  5. Raise the new front drive unit out of the front drive unit crate.
  6. Move the front subframe and subframe lift to underneath the new front drive unit.
  7. With the help of an assistant, use the gantry to lower the drive unit sling tool, guide halfshafts away from the new front drive unit, and lower the new front drive unit into the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the front drive unit rear support posts are in the same position as when the old front drive unit was lifted.
  8. Install the bolt that attaches the new front drive unit to the front of the front subframe.
    80 Nm (59.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise and lower the new front drive unit as necessary to ease installation of the bolt.
  9. Lower the drive unit sling tool to put slack into the drive sling tool cables.
  10. Open the shackles (x3) and remove the drive unit sling tool from the new front drive unit.
  11. Move the gantry back to the old drive unit.
  12. Use the shackles (x3) to attach the drive unit sling tool to the old front drive unit.
  13. Use the gantry to raise the drive unit sling tool, and then move the front drive unit crate to under the old front drive unit.
  14. Carefully lower the old front drive unit into the crate.
  15. Install and hand-tighten the bolts (x3) that attach the old front drive unit to the front drive unit crate.
  16. Lower the drive unit sling tool to release tension in the cables, and then remove the sling tool from the gantry.
  17. Open the shackles (x3) and remove the drive unit sling tool from the old front drive unit.
  18. Close the crate and prepare for shipment to MRB.
  19. Align the splines of the RH halfshaft with those of the differential in the front drive unit and carefully insert the halfshaft into the drive unit with a clockwise-counterclockwise rocking motion.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the insertion of the halfshaft. If the halfshaft seems difficult to insert, back out, rotate the halfshaft about 10 to 20 degrees, and try again.
  20. Fold the RH knuckle inward and continue to install the RH front halfshaft into the front drive unit until a click is heard when the halfshaft fully engages the circlip inside the differential.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the insertion of the halfshaft. Make sure that the halfshaft enters the drive unit straight on. If the halfshaft seems difficult to insert, back out, rotate the halfshaft about 10 to 20 degrees, align the halfshaft straight on, and try again.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull back on the halfshaft where it enters the front drive unit, to verify that it is secure in the drive unit.
  21. Align the splines of the LH halfshaft with those of the differential in the front drive unit and carefully insert the halfshaft into the drive unit with a clockwise-counterclockwise rocking motion.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the insertion of the halfshaft. If the halfshaft seems difficult to insert, back out, rotate the halfshaft about 10 to 20 degrees, and try again.
  22. Fold the LH knuckle inward and continue to install the LH front halfshaft into the front drive unit until a click is heard when the halfshaft fully engages the circlip inside the differential.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the insertion of the halfshaft. Make sure that the halfshaft enters the drive unit straight on. If the halfshaft seems difficult to insert, back out, rotate the halfshaft about 10 to 20 degrees, align the halfshaft straight on, and try again.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull back on the halfshaft where it enters the front drive unit, to verify that it is secure in the drive unit.
  23. Connect the subframe electrical harness to the oil pump connector, and then press the red locking tab into the connector.
  24. Fasten the clip that attaches the subframe electrical harness to the front drive unit motor.
    Figure 11. Heat Pump Model 3
    Figure 12. Model 3
  25. Fasten the clips (x2) that attach the subframe electrical harness to the inverter.
  26. Connect the subframe electrical harness to the front drive unit inverter logic connector, raise the handle upward, and then fasten the locking tab.
  27. Install the front drive unit inverter inlet hose to the front drive unit, and then fasten the clips (x2) that attach the hose to the drive unit.
  28. Connect the front drive unit inverter inlet hose to the front drive unit inverter inlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  29. Install the front drive unit inverter to heat exchanger hose to the front drive unit, and then fasten the clips (x2) that attach the hose to the drive uint.
    Figure 13. Heat Pump Model 3
    Figure 14. Model 3
  30. Connect the front drive unit inverter to heat exchanger hose to the front drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
    Figure 15. Heat Pump Model 3
    Figure 16. Model 3
  31. Connect the front drive unit inverter to heat exchanger hose to the front drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
    Figure 17. Heat Pump Model 3
    Figure 18. Model 3
  32. Install the front subframe. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
  33. Install the front fascia. See Fascia - Front (Remove and Install).
  34. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  35. Install the front LH and RH wheels. See Wheel Assembly (Remove and Install).
  36. Model 3 - Connect the electrical harness to the LV logic connectors (x2) at the steering gear, and then push the grey tabs to lock the connectors.
  37. Connect the electrical harness to the steering gear power connectors (x2), and then slide the red tab to lock the connectors.
  38. Model 3 - Connect the electrical harness to the front subframe electrical harness.
  39. Slide the intermediate shaft down onto the steering gear, and then install the bolt that attaches the intermediate shaft to the steering gear.
    18 Nm (13.3 lbs-ft)
    Figure 19. Heat Pump Model 3
    Figure 20. Model 3
  40. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  41. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  42. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  43. Remove the steering wheel lock from the steering wheel.
  44. Connect the laptop with Toolbox 3.
  45. In Toolbox 3, from the After Front Drive Unit Replacement Action List, click Stop Thermal Fluid Fill/Drain, click Run, and then allow the routine to complete.
  46. From the After Front Drive Unit Replacement Action List, click Service CAN Redeploy, click Run, and then allow the routine to complete.
  47. From the After Front Drive Unit Replacement Action List, click Coolant Air Purge, click RUN, and then allow the routine to complete.
  48. Inspect the coolant level and top up if necessary. See Cooling System (Partial Refill and Bleed).
  49. From the After Front Drive Unit Replacement Action List, click Thermal System Performance Test, click Run, and then allow the routine to complete.
  50. Disconnect the laptop with Toolbox 3 from the vehicle.
  51. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  52. For China, Japan and Korea only: Carefully remove the old motor label from the hood, and install a new motor label to match the new motor information.
  53. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  54. Check the vehicle wheel alignment, and adjust if necessary. See Four Wheel Alignment Check.