05/04/2024 15:42:34

Gearbox Fluid - Front Drive Unit (Drain and Refill)

Correction code 39300102 0.84 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.

  • 2024-04-05: Updated gearbox fluid information with link.
  • 2024-02-27: Updated gearbox fluid to KAF 1.
  • 2023-10-26: Updated the oil pump/filter removal steps; added torque info for all relevant steps.

Torque Specifications

Table 1. Torque Specifications: Gearbox Fluid - Front Drive Unit (Drain and Refill)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the front drive unit to the front subframe
80 Nm (59.0 lbs-ft)
  • 18 mm socket
  • Flex head ratchet/flex head torque wrench
Reuse
Bolts (x2) that attach the front drive unit oil pump to the front drive unit
5 Nm (3.7 lbs-ft) + 20 degrees
  • 4 in extension
  • EPL 10 socket
  • ¼ in to 3/8 in adapter
Reuse
Front drive unit fill plug
15 Nm (11.1 lbs-ft)
  • Ratchet/torque wrench
  • 8 mm hex
Reuse
New oil filter
3 Nm (2.2 lbs-ft) + 135 degrees
  • 21 mm socket
  • ¼ in to 3/8 in adapter
  • Torque Wrench 1/4in Dr. + Angle
  • Oil filter socket

Drain

  1. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Open all doors and lower all windows.
  3. Note the position of the driver and front passenger seats, and then move the seats fully forward.
  4. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  7. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  8. Support the LH side of the front drive unit with an underhoist stand, as shown.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Place a show towel between the underhoist stand and front drive unit.
  9. Remove the bolt that attaches the front drive unit to the front subframe.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  10. Position an oil drain container underneath the front drive unit oil filter and oil pump.
  11. Release the gray locking tab, and then press down on the tab to disconnect the oil pump connector.
  12. Carefully lower the front underhoist stand until the front drive unit oil pump is accessible.
  13. Remove the bolts (x2) that attach the front drive unit oil pump to the front drive unit.
    Tip: Use of the following tool(s) is recommended:
    • 4 in extension
    • EPL 10 socket
    • ¼ in to 3/8 in adapter
  14. Remove the front drive unit oil pump.
    Tip: Use the front drive unit as a fulcrum to leverage out the oil pump.
  15. Use the oil filter socket to remove the oil filter from the front drive unit, and then allow the gearbox fluid to drain.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • Ratchet/torque wrench
    • Oil filter socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow at least 10 minutes for the gearbox fluid to drain from the front drive unit, or until a slow drip exits the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tesla recommends that the oil filter is replaced with a new one upon removal. Any oil filter with visible corrosion or leaks must be replaced.
  16. Remove the fill plug from the front drive unit.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 8 mm hex

Refill

  1. Inspect the seal on the oil filter, the O-ring on the fill plug, and O-rings (x3) on the oil pump.
    • Make sure that the O-ring is on the fill plug, the 3 O-rings are on the oil pump, and no O-rings are stuck in the front drive unit assembly.
    • If an O-ring is damaged on the oil pump, install a new O-ring.
    • If the O-ring is damaged on the fill plug, install a new fill plug or O-ring.
    • Check that the seal is on the oil filter and not on the front drive unit assembly.
  2. Apply a light coat of new gearbox fluid to the O-ring seal of a new oil filter, and then install the new filter onto the front drive unit.
    3 Nm (2.2 lbs-ft) + 135 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • ¼ in to 3/8 in adapter
    • Torque Wrench 1/4in Dr. + Angle
    • Oil filter socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Tesla recommends that the oil filter is replaced with a new one upon removal. Any oil filter with visible corrosion or leaks must be replaced.
  3. Lubricate the oil pump O-rings (x3) with new gearbox fluid, and then reinstall the oil pump onto the front drive unit assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
  4. Install the bolts (x2) that attach the oil pump to the front drive unit.
    5 Nm (3.7 lbs-ft) + 20 degrees
    Tip: Use of the following tool(s) is recommended:
    • 4 in extension
    • EPL 10 socket
    • ¼ in to 3/8 in adapter
  5. Carefully raise the front underhoist stand until the front drive unit front bushing aligns with the front subframe mount.
  6. Install the bolt that attaches the front drive unit to the front subframe.
    80 Nm (59.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  7. Remove the underhoist stand and shop towel from the LH side of the front drive unit.
  8. Using the measure and fill kit, fill the container with 1500 mL of new gearbox fluid.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
  9. Connect the 12V power supply to the oil pump using the oil pump switchbox special tool and the XP-10 jump pack.
  10. Cut both the input and output hoses of the fluid transfer pump to approximately 26" (66 cm).
  11. Insert the output hose of the fluid transfer pump into the fill hole of the front drive unit until fully seated, and then pull the output hose back 5mm.
  12. Set up the fill process by putting the container with the measured new gearbox fluid in the drain basket, and then fully submerge the input hose of the fluid transfer pump and prime the pump.
  13. With an assistant, pump new gearbox fluid into the front drive unit assembly as follows:
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
    Informational PurposesAn informational icon, calling your attention
    Note
    The minimum refill capacity of the front drive unit assembly is 1.3 liters. Using excess gearbox fluid in the fill container allows the oil pump to dispense the full 1.3L without drawing air. Make sure that there is less than 200mL left when completed. Pumping the full 1.5 liters is not required.
    1. Pump 5 full strokes from the fluid container with the manual pump.
    2. Run the oil pump via the switch box for the entire fill, and then keep running the oil pump until the fill plug is installed.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not run the oil pump dry.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      If the oil pump is not running and the fill plug is not installed, the gearbox fluid will drain from the fill plug within 10 seconds.
  14. Install the fill plug on the front drive unit.
    15 Nm (11.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 8 mm hex
  15. Disconnect the oil pump switchbox and XP-10 jump pack from the oil pump.
  16. Connect the oil pump connector, and then engage the gray locking tab.
    Important: Perform a push-pull test to verify that the connector is fully attached.
  17. Remove the oil drain container from underneath the front drive unit.
  18. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  19. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  20. Restore the driver and front passenger seat back to their original position.
  21. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  22. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  23. Connect a laptop with Toolbox 3 to the vehicle.
  24. In Toolbox, click the Actions/Autodiag tab, and then search for "Oil Pump Low Pressure Test - Front Drive Unit".
  25. Click TEST-SELF_DIF_X_OIL-PUMP-PRESSUREvia Toolbox: (link), and click Run, and then allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    This test might take up to 5 times to successfully run. If this test keeps failing, add additional fluid, if needed.
  26. Disconnect Toolbox 3 and remove the laptop from the vehicle.
  27. Exit Service Mode through UI.
  28. Remove the vehicle from the lift.