22/05/2024 15:34:41

Subframe Assembly - Rear (4DU) (Remove and Replace)

Correction code 30010222 3.01 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.

  • 2024-04-16: Added a tool list.
  • 1090880-00-A Steering Wheel Holder **Std. w/ Hunter Alignment Equip.**
  • 1099645-00-C Fixture, Subframe, Model 3
  • 1066521-00-A OTC Lift, 1,650LB Powertrain Table
  • 10821717-00-A S-Hook
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. Chock a front wheel to prevent the vehicle from rolling in subsequent steps.
  3. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  4. In Toolbox 3, click the Actions tab, type "EPB" in the search field, click Start EPBL Service Mode, click Run, and allow the routine to complete.
  5. Hold down the brake pedal, click Start EPBR Service Mode, click Run, and allow the routine to complete.
  6. Click the Actions tab, type "Thermal" in the search field, click Start Thermal Fluid Fill/Drain (Coolant only), click Run, and allow the routine to complete.
  7. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  8. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  9. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  10. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  11. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  12. Remove the LH and RH rear wheels. See Wheel (Remove and Replace).
  13. Remove the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  14. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  15. Remove the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  16. 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.
  17. Remove and discard the bolts (x2) that attach the LH rear brake caliper to the LH rear knuckle, remove the caliper from the knuckle, and then hang the caliper from an S-hook.
  18. Install the Gedore spring compressor onto the LH rear coil spring, and slightly compress the spring to take the load off of the suspension.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to the Tooling Profile for additional information.
  19. Remove the bolts (x2) that attach the LH rear strut to the body at the LH top mount.
  20. Repeat step 17 through step 19 on the RH side of the vehicle.
  21. Disconnect the electrical harness from the rear subframe harness RH connector.
  22. Release the clip that attaches the rear subframe harness to the body on the RH side.
  23. Disconnect the electrical harness from the rear subframe harness LH connector.
  24. Release the clip that attaches the rear subframe harness to the body on the LH side.
  25. 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.
  26. 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.
  27. 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.
  28. 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.
  29. 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.
  30. Release the clips (x2) that attach the coolant hoses to LH shear plate.
  31. Release the clips (x4) that attach the coolant hoses to the rear skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clip quantity varies with older vehicles.
  32. Release the clips (x2) that attach the coolant hoses to RH shear plate.
  33. Remove the HV battery rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  34. Position a coolant drain collector underneath the LH rear of the HV battery.
  35. Release the clip, disconnect the rear drive unit inverter inlet hose from the HV battery, and then immediately plug both fittings.
  36. Release the clip, disconnect the rear drive unit inverter inlet hose from the rear drive unit inverter, and then immediately plug both fittings.
  37. Release the clip that attaches the rear drive unit inverter inlet hose from rear drive unit HV harness.
  38. Remove the rear drive unit inverter inlet hose down and out from between the rear subframe and the HV battery.
  39. Position a coolant drain collector underneath the RH rear of the HV battery.
  40. Release the clips (x2) that attach the RH rear wheel arch liner to the RH rocker panel, and then move the liner aside for access.
  41. Release the clip, disconnect the rear drive unit coolant outlet hose from the powertrain return hose, and then immediately plug both fittings.
  42. Remove the coolant drain collector from under the vehicle.
  43. 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.
  44. Release the clip that attaches the rear subframe electrical harness to the rear drive unit inverter.
  45. Remove the bolt that attaches the rear drive unit HV harness bracket to the rear drive unit inverter.
  46. 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.
  47. Remove the nut(s) that attach(es) the rear drive unit HV harness bracket to the HV battery.
  48. Slide the red locking tab, raise the black handle, and then disconnect the rear drive unit HV harness from the HV battery header.
  49. 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.
  50. Position the subframe lifting tool under, and up against the rear subframe.
  51. With the help of an assistant, fully secure the straps (x3) that attach the rear subframe to the subframe lifting tool.
  52. 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.
  53. 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.
  54. Remove the small bolts (x2) that attach the LH shear plate to the HV battery.
  55. Remove the large bolt that attaches the LH shear plate and rear subframe to the body, and then remove shear plate.
  56. Remove the small bolts (x2) that attach the RH shear plate to the HV battery.
  57. Remove the large bolt that attaches the RH shear plate and rear subframe to the body, and then remove shear plate.
  58. Remove and discard the LH rear subframe bolt that attaches the subframe to the body.
  59. Carefully lower the rear subframe and rear drive unit assembly from the vehicle, and move it out from under the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage hoses or harnesses while lowering the subframe.

Install

  1. Position the rear subframe and rear drive unit assembly under the vehicle.
  2. 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
    Do not damage hoses or harnesses while raising the subframe.
  3. Install and hand-tighten a new RH rear subframe bolt to attach the rear subframe to the body.
  4. Install and hand-tighten a new LH rear subframe bolt to attach the rear subframe to the body.
  5. 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.
  6. Install and hand-tighten the small bolts (x2) that attach the RH shear plate to the HV battery.
  7. 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.
  8. Install and hand-tighten the small bolts (x2) that attach the LH shear plate to the HV battery.
  9. 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.
  10. Tighten the RH rear subframe bolt that attaches the rear subframe to the body, and then mark the bolt after tightenting.
    165 Nm (121.7 lbs-ft)
  11. Tighten the LH rear subframe bolt that attaches the rear subframe to the body, and then mark the bolt after tightenting.
    165 Nm (121.7 lbs-ft)
  12. Tighten large bolt that attaches the LH shear plate and rear subframe to the body, and then mark the bolt after tightenting.
    130 Nm (95.9 lbs-ft)
  13. Tighten large bolt that attaches the RH shear plate and rear subframe to the body, and then mark the bolt after tightenting.
    130 Nm (95.9 lbs-ft)
  14. Tighten the small bolts (x2) that attach the LH and RH shear plate to the HV battery.
    Figure 1. LH side shown, RH side similar
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
  15. Release the straps (x3) that attach the rear subframe to the subframe lifting tool.
  16. Lower the subframe lifting tool, and move it out from under the vehicle.
  17. 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.
  18. 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.
  19. Install the nut(s) that attach(es) the rear drive unit HV harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
  20. 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.
  21. Install the bolt that attaches the rear drive unit HV harness bracket to the rear drive unit inverter.
    6 Nm (4.4 lbs-ft)
  22. 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.
  23. Connect the rear subframe electrical harness to the rear drive unit inverter logic connector, raise the handle upward, and fasten the locking tab.
  24. Fasten the clip that attaches the rear subframe electrical harness to the rear drive unit inverter.
  25. Position a coolant drain collector underneath the LH rear of the HV battery.
  26. Install the rear drive unit inverter inlet hose in and up between the rear subframe and the HV battery.
  27. Fasten the clip that attaches the rear drive unit inverter inlet hose to rear drive unit HV harness.
  28. 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.
  29. 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.
  30. Position the coolant drain collector underneath the RH rear of the HV battery.
  31. Remove the plugs from the fittings, immediately connect the rear drive unit coolant outlet hose to the powertrain return hose, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  32. Return the RH rear wheel arch liner to position, and then fasten the clips (x2) that attach the liner to the RH rocker panel.
  33. Remove the coolant drain collector from under the vehicle.
  34. Install the HV battery rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  35. Fasten the clips (x2) that attach the coolant hoses to RH shear plate.
  36. Fasten the clips (x4) that attach the coolant hoses to the rear skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clip quantity varies with older vehicles.
  37. Fasten the clips (x2) that attach the coolant hoses to LH shear plate.
  38. 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)
  39. 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.
  40. 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.
  41. 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.
  42. 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.
  43. Fasten the clip that attaches the rear subframe harness to the body on the LH side.
  44. Connect electrical harness to the rear subframe harness LH connector.
  45. Fasten the clip that attaches the rear subframe harness to the body on the RH side.
  46. Connect electrical harness to the rear subframe harness RH connector.
  47. 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)
  48. Install the LH rear strut to the body at the LH top mount, and then install the bolts (x2) that attach the strut to the body.
    41 Nm (30.2 lbs-ft)
  49. Remove the S-Hook, install the LH rear brake caliper to the LH rear knuckle, and then install new bolts (x2) to attach the caliper to the knuckle.
    83 Nm (61.2 lbs-ft)
  50. Remove the Gedore spring compressor from the LH rear coil spring.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to the Tooling Profile for additional information.
  51. Repeat step 48 through step 50 for the RH side of the vehicle.
  52. Install the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  53. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  54. Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  55. Install the LH and RH rear wheels. See Wheel (Remove and Replace).
  56. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  57. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  58. On the touchscreen, press and hold the Park button to disable EPB service mode, and then remove any wheel chocks.
  59. Connect the laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  60. In Toolbox 3, click the Actions tab, type "Thermal" in the search field, click Stop Thermal Fluid Fill/Drain, click Run, and allow the routine to complete.
  61. Click the Actions tab, type "Coolant" in the search field, click Coolant Air Purge, click Run, and allow the routine to complete.
  62. Click the Actions tab, type "Thermal" in the search field, click Thermal System Performance Test, click Run, and allow the routine to complete.
  63. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  64. Add coolant to the reservoir as necessary, and install the reservoir cap.
  65. Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  66. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  67. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  68. Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.