01/04/2024 14:02:04

Heat Exchanger - Rear Drive Unit (Long Range) (Remove and Replace)

Correction code 40305202 1.08 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 proper PPE is worn when performing the below procedure.

  • 2024-02-06: Updated gearbox fluid to KAF1.
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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. Raise and support vehicle.
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    Note
    Set air suspension to "Jack Mode".
  2. Open hood.
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    Note
    Using center display touchscreen > Quick Controls > Frunk Open.
  3. Remove rear underhood apron.
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    8x clips.
  4. Power off vehicle from center display.
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    Via Controls > Safety & Security > Power Off.
  5. Disconnect LV battery connector and First Responder Loop.
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    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection.
  6. Raise vehicle fully and lower lift onto locks.
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    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  7. Remove clips securing mid aero shield.
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    Note
    4x push clips.
  8. Remove bolts securing mid aero shield and remove from vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  9. Disconnect oil pump connector.
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    Note
    1x connector, Pull grey tab to disengage lock then disconnect.
  10. Remove clips securing RH side of subframe harness to RDU.
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    2x clips.
  11. Position coolant drain underneath RH rear of vehicle.
  12. Disconnect PT return hose from RDU heat exchanger.
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    Note
    1x spring clip, Plug hose and heat exchanger as needed.
  13. Remove clip securing PT return hose to RDU heat exchanger.
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    Note
    1x clip.
  14. Disconnect inverter to oil cooler hose from RDU heat exchanger.
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    Note
    1x spring clip, Plug hose and heat exchanger as needed.
  15. Remove clip securing inverter to oil cooler hose to RDU heat exchanger.
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    Note
    1x clip.
  16. Remove bolts securing heat exchanger to rear drive unit.
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    Note
    2x bolts, EP10, 5 Nm and 30 degrees.
  17. Remove RDU heat exchanger.
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    Note
    Do not pry against RDU or heat exchanger, Damage may occur, It may be necessary to gently work heat exchanger up and down to free it from RDU, Do not allow coolant to enter RDU oil passages, Prevent cross-contamination.

Install

  1. Position RDU heat exchanger.
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    Note
    Lightly coat O-rings with clean KAF1 gearbox fluid, Do not pinch or deform O-ring during install, Ensure heat exchanger is fully seated, Do not allow coolant to enter RDU oil passages, Prevent cross-contamination.
  2. Install bolts securing heat exchanger to rear drive unit.
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    Note
    2x bolts, EP10, 5 Nm and 30 degrees.
  3. Install clip securing inverter to oil cooler hose to RDU heat exchanger.
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    Note
    1x clip.
  4. Install inverter to oil cooler hose onto RDU heat exchanger.
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    Note
    1x spring clip, Remove plugs from both ends of each coolant connection, Perform push-pull-push test to make sure hose is fully seated.
  5. Install clip securing PT return hose to RDU heat exchanger.
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    1x clip.
  6. Install PT return hose onto RDU heat exchanger.
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    Note
    1x spring clip, Remove plugs from both ends of each coolant connection, Perform push-pull-push test to make sure hose is fully seated.
  7. Remove coolant drain container from underneath vehicle.
  8. Position oil drain container under RDU drain valve.
  9. Remove fill plug from RDU.
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    Note
    1x plug, 8mm allen, 15 Nm.
  10. Remove fasteners securing RDU oil pump.
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    Note
    2x bolts, EP10, 5 Nm and 20 degrees.
  11. Remove RDU oil pump assembly.
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    Note
    Pry the pump away from the RDU, Be cautious when prying to avoid damage to plastic and casting, Allow the oil to drain from the RDU.
  12. Remove RDU oil filter.
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    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.
  13. Inspect seals and O-rings.
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    Inspect O-rings on removed parts, 3 O-rings on pump, one O-ring on fill plug, if missing O-ring on pump ensure it is not left in housing, if damaged O-ring on plug replace affected plug, Replace all O-rings on oil pump if damaged, Check seal on oil filter, if missing check if still on housing and remove before install.
  14. Install new RDU oil filter.
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    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.
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    Spin clockwise, 3 Nm and 135 degrees, Lubricate seal prior to installation.
  15. Install RDU oil pump assembly.
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    Note
    Inspect O-rings for damage and verify none are stuck inside the drive unit casting, Replace O-rings if necessary, Lightly coat O-rings with clean fluid.
  16. Install fasteners securing RDU oil pump.
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    Note
    2x bolts, EP10, 5 Nm and 20 degrees.
  17. Set up fill kit with KAF1 fluid.
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    Fill measuring container to 2.3L / 2300 mL - Long range rear drive unit will take 2.1L of fluid.
  18. Install fluid transfer pump.
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    Trim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm.
  19. Set up fill process.
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    Place measured fluid container in drain basket, Fully submerge input hose, Prime pump with drive unit fluid.
  20. Connect 12V power supply to RDU oil pump.
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    1x connector, Engage locking tab.
  21. Pump fluid into rear drive unit.
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    Note
    Recommend assistance, Do not run oil pump dry, Pump fluid into drive unit, Run oil pump in between to cycle fluid, The minimum refill capacity of the rear drive unit assembly is 2.1L, Using excess gearbox fluid in the fill container allows the oil pump to dispense the full 2.1L without drawing air, Make sure that there is less than 200mL left when completed, Pumping the full 2.3L is not required.
  22. Install fill plug onto RDU.
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    1x plug, 8mm Allen, 15 Nm, .
  23. Disconnect 12V power supply from RDU oil pump.
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    Note
    1x connector.
  24. Install clips securing RH side of subframe harness to RDU.
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    2x clips.
  25. Connect oil pump connector.
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    1x connector, Engage locking tab.
  26. Spray area with brake cleaner and wipe residual fluid off with towel.
  27. Remove oil drain container from underneath vehicle.
  28. Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  29. Install clips securing mid aero shield.
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    Note
    4x push clips.
  30. Lower vehicle fully.
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  31. Remove coolant bottle cap.
  32. Inspect coolant level and top off as necessary.
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    Ensure that the fluid level is at the Max line, Top off fluid as required.
  33. Connect First Responder Loop and LV battery connector.
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    2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated.
  34. Release IP service panel.
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    2x tabs, 4x datums, Release top tabs and slide rearward.
  35. Using laptop connect to vehicle with ethernet diag kit and Toolbox 3.
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    Open Toolbox 3 website and establish connection to the vehicle. Media converter box is powered by laptop USB or 12v power outlet, Ethernet connection will provide communication.
  36. Select Actions/Autodiag tab and search for ‘Purge'.
  37. Select TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeDrive Inverter / Front Drive Inverter Replacement - Coolant Air PurgeDrive Inverter / Rear Drive Inverter Replacement - Coolant Air PurgeDrive Inverter / Rear Left Drive Inverter Replacement - Coolant Air PurgeDrive Inverter / Rear Right Drive Inverter Replacement - Coolant Air PurgeDrive Unit / Front Drive Unit Replacement - Coolant Air PurgeDrive Unit / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge StartThermal / Coolant System - Coolant Purge Start, click Run, and allow routine to complete.
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    Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required.
  38. Select Actions/Autodiag tab and search for "Oil Pressure".
  39. Select TEST-SELF_DIR_X_OIL-PUMP-PRESSURESearch for routine in ToolboxOil Pump Low Pressure Test - Rear Drive Unit, click Run, and allow routine to complete.
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    If this test is failing, add additional fluid and retest. Select "X" at top right of window to close once complete.
  40. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit.
  41. Install IP service panel.
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    2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP.
  42. Inspect coolant level and top off as necessary.
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    Note
    Ensure that the fluid level is at the Max line.
  43. Install coolant bottle cap.
  44. Install rear underhood apron.
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    Note
    8x clips.
  45. Close hood .
  46. Remove vehicle from lift.
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    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".