22/05/2024 15:36:11
Drive Unit - Rear (4DU) (Remove and Install)
Correction code 40011011 2.75 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.
- 2024-01-12: Updated torque figure for the bolt that attaches the ground strap to the RDU from 6 Nm to 10 Nm.
- 2023-05-02: Corrected step crossreferences.
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
- While performing the courtesy inspection, note any abnormal tire wear that could indicate the need for an alignment.
- Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
- Chock a front wheel to prevent the vehicle from rolling in subsequent steps.
- Enable Service Mode from the touchscreen. See Service Mode.
- From the touchscreen, touch , and allow the routine to complete.
- From the touchscreen, touch , and allow the routine to complete.
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
- Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Remove the LH and RH rear wheels. See Wheel (Remove and Replace).
- Remove the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
- Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Remove the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
- 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.
- 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.
-
Install the Gedore spring compressor
onto the LH rear coil spring, and slightly compress the spring to take the load off of
the suspension.
NoteRefer to the Tooling Profile for additional information.
- Remove the bolts (x2) that attach the LH rear strut to the body at the LH top mount.
- Repeat step 16 through step 18 on the RH side of the vehicle.
- Disconnect the electrical harness from the rear subframe harness RH connector.
- Release the clip that attaches the rear subframe harness to the body on the RH side.
- Disconnect the electrical harness from the rear subframe harness LH connector.
- Release the clip that attaches the rear subframe harness to the body on the LH side.
-
Remove and discard the nut that
attaches the LH rear stabilizer bar end link to the rear stabilizer bar.
NoteUse a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
-
Remove LH rear stabilizer bar end link
from the rear stabilizer bar.
NoteMove the stabilizer bar up and down to ease removal of the end link.
-
Remove and discard the nut that
attaches the RH rear stabilizer bar end link to the rear stabilizer bar.
NoteUse a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
-
Remove RH rear stabilizer bar end link
from the rear stabilizer bar.
NoteMove the stabilizer bar up and down to ease removal of the end link.
- 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.
- Release the clips (x2) that attach the coolant hoses to LH shear plate.
-
Release the clips (x4) that attach the
coolant hoses to the rear skid plate.
NoteClip quantity varies with older vehicles.
- Release the clips (x2) that attach the coolant hoses to RH shear plate.
- Remove the HV battery rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
- Position a coolant drain collector underneath the LH rear of the HV battery.
- Release the clip, disconnect the rear drive unit inverter inlet hose from the HV battery, and then immediately plug both fittings.
- Release the clip, disconnect the rear drive unit inverter inlet hose from the rear drive unit inverter, and then immediately plug both fittings.
- Release the clip that attaches the rear drive unit inverter inlet hose from rear drive unit HV harness.
- Remove the rear drive unit inverter inlet hose down and out from between the rear subframe and the HV battery.
- Position a coolant drain collector underneath the RH rear of the HV battery.
- 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.
- Release the clip, disconnect the rear drive unit coolant outlet hose from the powertrain return hose, and then immediately plug both fittings.
- Remove the coolant drain collector from under the vehicle.
-
Release the locking tab, push the
handle downward, and then disconnect the rear subframe electrical harness from the rear
drive unit inverter logic connector.
CAUTIONOnce disconnected, make sure that coolant does not get into the connectors.
- Release the clip that attaches the rear subframe electrical harness to the rear drive unit inverter.
- Remove the bolt that attaches the rear drive unit HV harness bracket to the rear drive unit inverter.
- 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.
- Remove the nut(s) that attach(es) the rear drive unit HV harness bracket to the HV battery.
- Slide the red locking tab, raise the black handle, and then disconnect the rear drive unit HV harness from the HV battery header.
-
Remove the rear drive unit HV harness
down and out from between the rear subframe and the HV battery.
NoteRotate the harness as it is removed to allow access for the bracket.
- Position the subframe lifting tool under, and up against the rear subframe.
- With the help of an assistant, fully secure the straps (x3) that attach the rear subframe to the subframe lifting tool.
- 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.
- 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.
- Remove the small bolts (x2) that attach the LH shear plate to the HV battery.
- Remove the large bolt that attaches the LH shear plate and rear subframe to the body, and then remove shear plate.
- Remove the small bolts (x2) that attach the RH shear plate to the HV battery.
- Remove the large bolt that attaches the RH shear plate and rear subframe to the body, and then remove shear plate.
- Remove and discard the LH rear subframe bolt that attaches the subframe to the body.
-
Carefully lower the rear subframe and
rear drive unit assembly from the vehicle, and move it out from under the vehicle.
CAUTIONDo not damage hoses or harnesses while lowering the subframe.
- Release the clip that attaches the rear drive unit ground strap to the rear subframe.
-
Remove the bolt that attaches the rear
drive unit ground strap to the rear drive unit, and then remove the ground strap from
the drive unit.
-
Position a coolant catcher under the
RH side of the subframe and rear drive unit assembly, and position a foldable funnel to
direct coolant drain from the heat exchanger.
- Release the clip, disconnect the rear drive unit coolant outlet hose from the rear drive unit heat exchanger, and allow the heat exchanger and hose to drain.
- Release clips (x3) that attach the rear drive unit coolant outlet hose to rear drive unit, and then manuever the hose out from between the drive unit and rear subframe.
- Release the clips (x2) that attach the rear drive unit inverter outlet to heat exchanger hose to the rear drive unit.
-
Cut the rear drive unit inverter NVH
cover at the line indicated so as to access the clip for the rear drive unit inverter to
heat exchanger hose.
NoteOpen the cut in the NVH cover, but be carefull not to remove any of the cover in doing so.
- Release the clip, disconnect the rear drive unit inverter to heat exchanger hose from the rear drive unit inverter outlet, and allow to drain.
- Release the clip, disconnect the rear drive unit inverter to heat exchanger hose from the rear drive unit heat exchanger, and allow to drain.
- Release the remaining clips (x2) that attach the rear drive unit inverter outlet to heat exchanger hose to the rear drive unit, and then manuever the hose out from between the drive unit and rear subframe.
- Pull the red tab to release, and then pull the red tab again to disconnect the rear subframe harness from the oil pump connector.
- Pull the red tab to release, pull the red tab again to disconnect the rear subframe harness from the resolver connector, and then release the clips (x2) that attach the subframe harness to the rear drive unit.
- Remove the bolt that attaches the LH rear wheel speed sensor to LH rear knuckle, and then remove the sensor from the knuckle.
- Release the grommet that attaches the LH rear wheel speed sensor harness to LH rear knuckle.
- Remove the nut and bolt that attach the LH rear upper aft link to the LH rear knuckle.
- Remove the nut and bolt that attach the LH rear upper fore link to the LH rear knuckle.
- Remove the nut and bolt that attach the LH rear toe link to the LH rear knuckle.
- Loosen, but do not remove, the nut and bolt that attach the LH rear lower fore link to the LH rear knuckle.
- Position the axle remover cable around the inner joint of the LH rear drive unit halfshaft, and then use the U-bolt to hold the axle remover cable in position.
-
Hook the axle remover slide hammer
onto the 2 axle remover cable loops, and then use the slide hammer to remove the LH
halfshaft from the rear drive unit.
NoteBe carefull not to damage the halfshaft boots and drive unit seals when separating the halfshaft from the drive unit.
- Repeat step 71 through step 78 on the RH side of the rear subframe assembly.
-
Position the rear subframe assembly
under the gantry.
- Use the shackles (x3) to attach the drive unit sling tool to the rear drive unit.
- Attach the drive unit sling tool to the gantry.
-
Use the gantry to raise the drive unit
sling tool so that there is slight tension in the cables.
- Remove the bolt that attaches the rear drive unit to the LH side of the rear subframe.
- Remove the bolt that attaches the rear drive unit to the RH side of the rear subframe.
- Remove the bolt that attaches the rear drive unit to the rear of the rear subframe.
- With the help of an assistant, use the gantry to raise the rear drive unit sling tool, guide halfshafts away from the rear drive unit, and separate the rear drive unit up from the rear subframe.
- Move the rear subframe and subframe lift out from underneath the rear drive unit, and then lower the rear drive unit onto a protected surface.
- Remove the drive unit sling tool from the rear drive unit.
Install
- Use the shackles (x3) to attach the drive unit sling tool to the rear drive unit.
- Use the gantry to lift the rear drive unit off of the protective surface and position the rear subframe and subframe lift underneath the drive unit.
- With the help of an assistant, use the gantry to lower the rear drive unit sling tool, guide halfshafts into the rear drive unit, and lower the rear drive unit into the rear subframe.
- Lower the rear drive unit sling tool so as to install and hand tighten the bolt that attaches the rear drive unit to the rear of the rear subframe.
- Install and hand tighten the bolt that attaches the rear drive unit to the RH side of the rear subframe.
- Install and hand tighten the bolt that attaches the rear drive unit to the LH side of the rear subframe.
- Lower the drive unit sling tool to release tension in the cables, and then remove the sling tool from the rear drive unit.
- Remove the drive unit sling tool from the gantry.
-
Tighten the rear drive unit mount
bolts (x3).
-
With the help of an assistant,
slightly rotate the LH halfshaft so as to align the splines of the halfshaft to those in
the rear drive unit, lift up on the LH rear knuckle to help move the halfshaft into the
drive unit, and then apply force to seat the halfshaft in the drive unit.
NoteIf the halfshaft binds, back the halfshaft out, rotate it slightly, and try again.NoteA snap is heard when the retaining clip seats onto the fully inserted halfshaft.
- Install the LH rear toe link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
- Install the LH rear upper fore link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
- Install the LH rear upper aft link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
- Fasten the grommet that attaches the LH rear wheel speed sensor harness to LH rear knuckle.
-
Install the LH rear wheel speed sensor
to LH rear knuckle, and then install the bolt that attaches the sensor to
knuckle.
- Repeat step 10 through step 15 on the RH side of the rear subframe assembly.
- Connect the rear subframe harness to the resolver connector, push the red tab to secure, and then fasten the clips (x2) that attach the subframe harness to the rear drive unit.
- Connect the rear subframe harness to the oil pump connector, and then push the red tab to secure.
- Manuever the rear drive unit inverter outlet to heat exchanger hose in between the rear drive unit and rear subframe, and then fasten the clips (x2) that attach the hose to the drive unit.
- Connect the rear drive unit inverter to heat exchanger hose to the rear drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
- 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.
- Fasten the clips (x2) that attach the rear drive unit inverter outlet to heat exchanger hose to the rear drive unit.
- Manuever the rear drive unit coolant outlet hose in between the rear drive unit and rear subframe, and then fasten the clips (x3) that attach the hose to drive unit.
- Connect the rear drive unit coolant outlet hose to the rear drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
-
Install the rear drive unit ground
strap to the rear drive unit, and then install the bolt that attaches the ground strap
to the drive unit.
- Fasten the clip that attaches the rear drive unit ground strap to the rear subframe.
-
Position the rear subframe and rear
drive unit assembly under the vehicle.
-
Carefully raise the subframe and rear
drive unit assembly until they are up against the body.
CAUTIONDo not damage hoses or harnesses while raising the subframe.
- Install and hand-tighten a new RH rear subframe bolt to attach the rear subframe to the body.
- Install and hand-tighten a new LH rear subframe bolt to attach the rear subframe to the body.
- 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.
- Install and hand-tighten the small bolts (x2) that attach the RH shear plate to the HV battery.
- 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.
- Install and hand-tighten the small bolts (x2) that attach the LH shear plate to the HV battery.
- 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.
-
Tighten the RH rear subframe bolt that
attaches the rear subframe to the body, and then mark the bolt after
tightenting.
-
Tighten the LH rear subframe bolt that
attaches the rear subframe to the body, and then mark the bolt after
tightenting.
-
Tighten large bolt that attaches the
LH shear plate and rear subframe to the body, and then mark the bolt after
tightenting.
-
Tighten large bolt that attaches the
RH shear plate and rear subframe to the body, and then mark the bolt after
tightenting.
-
Tighten the small bolts (x2) that
attach the RH shear plate to the HV battery.
-
Tighten the small bolts (x2) that
attach the LH shear plate to the HV battery.
- Release the straps (x3) that attach the rear subframe to the subframe lifting tool.
- Lower the subframe lifting tool, and move it out from under the vehicle.
-
Install the rear drive unit HV harness
in and up between the rear subframe and the HV battery.
NoteRotate the harness as it is installed to allow access for the bracket.
- 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.
-
Install the nut(s) that attach(es) the
rear drive unit HV harness bracket to the HV battery.
- 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.
-
Install the bolt that attaches the
rear drive unit HV harness bracket to the rear drive unit inverter.
- 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.
- Connect the rear subframe electrical harness to the rear drive unit inverter logic connector, raise the handle upward, and fasten the locking tab.
- Fasten the clip that attaches the rear subframe electrical harness to the rear drive unit inverter.
- Position a coolant drain collector underneath the LH rear of the HV battery.
- Install the rear drive unit inverter inlet hose in and up between the rear subframe and the HV battery.
- Fasten the clip that attaches the rear drive unit inverter inlet hose to rear drive unit HV harness.
- 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.
- 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.
- Position the coolant drain collector underneath the RH rear of the HV battery.
- 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..
- Return the RH rear wheel arch liner to position, and then fasten the clips (x2) that attach the liner to the RH rocker panel.
- Remove the coolant drain collector from under the vehicle.
- Install the HV battery rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
- Fasten the clips (x2) that attach the coolant hoses to RH shear plate.
-
Fasten the clips (x4) that attach the
coolant hoses to the rear skid plate.
NoteClip quantity varies with older vehicles.
- Fasten the clips (x2) that attach the coolant hoses to LH shear plate.
-
Install the rear stabilizer bar to the
rear subframe, and then install new bolts (x4) to attach the stabilizer bar to the
subframe.
-
Install the LH rear stabilizer bar end
link into the rear stabilizer bar.
NoteMove the stabilizer bar up and down to ease installation of the end link.
-
Install a new nut to attach the LH
rear stabilizer bar end link to the rear stabilizer bar.NoteUse a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
-
Install the RH rear stabilizer bar end
link into the rear stabilizer bar.
NoteMove the stabilizer bar up and down to ease installation of the end link.
-
Install a new nut to attach the RH
rear stabilizer bar end link to the rear stabilizer bar.NoteUse a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
- Fasten the clip that attaches the rear subframe harness to the body on the LH side.
- Connect electrical harness to the rear subframe harness LH connector.
- Fasten the clip that attaches the rear subframe harness to the body on the RH side.
- Connect electrical harness to the rear subframe harness RH connector.
-
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.
-
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.
-
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.
- Remove the bolt that attaches the LH rear brake rotor to the hub.
- Install the hub jack adapter onto the LH rear hub and hand-tighten the lug nuts (x5).
- Use an underhoist stand to support the hub jack adapter and simulate the LH rear suspension at ride height.
-
Use the rear ride height torque gauge
to verify the LH rear suspension is set to ride height specification.
NoteIt may be necessary to slightly adjust the underhoist stand or Gedore spring compressor tool.
-
The distance between the bottom of the
quarter panel and the center of the rear axle should be 427 mm when the rear suspension
is set to ride height.
NoteIt may be necessary to slightly adjust the underhoist stand or Gedore spring compressor tool.
-
Tighten the bolt and nut that attach
the LH rear upper aft link to the knuckle, and then mark the fasteners with a paint pen
after tightening
-
Tighten the bolt and nut that attach
the LH rear upper fore link to the knuckle, and then mark the fasteners with a paint pen
after tightening
-
Tighten the bolt and nut that attach
the LH rear toe link to the knuckle, and then mark the fasteners with a paint pen after
tightening
-
Tighten the bolt and nut that attach
the LH rear lower fore link to the knuckle, and then mark the fasteners with a paint pen
after tightening
- Remove the underhoist stand from underneath the LH rear suspension.
- Remove the lug nuts (x5) that attach the hub jack adapter, and then remove the hub jack adapter from the vehicle.
-
Install the bolt that attaches the LH
rear brake rotor to the hub.
-
Remove the Gedore spring compressor
from the LH rear coil spring.
NoteRefer to the Tooling Profile for additional information.
- Repeat step 75 through step 89 for the RH side of the vehicle.
- Install the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
- Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
- Install the LH and RH rear wheels. See Wheel (Remove and Replace).
- Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
- Connect LV power. See 12V/LV Power (Disconnect and Connect).
- On the touchscreen, press and hold the Park button to disable EPB service mode, and then remove any wheel chocks.
- From the touchscreen, touch , and allow the routine to complete.
- From the touchscreen, touch Run, and allow the routine to complete. , touch
- Add coolant to the reservoir as necessary, and install the reservoir cap.
- From the touchscreen, touch Run, and allow the routine to complete. , touch
- Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Disable Service Mode. See Service Mode.
- Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
- 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.