01/04/2024 14:03:25

Oil Pump - Rear Drive Unit (Long Range) (Remove and Replace)

Correction code 40304602 0.54 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.
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.
  1. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
  2. Open LH front door
  3. Lower LH front window
  4. Open hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Center Display > Controls > Frunk Open
  5. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  6. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Controls > Safety & Security > Power Off
  7. Disconnect LV battery connector and First Responder Loop
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection
  8. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  9. Remove clips securing mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  10. Remove bolts securing mid aero shield and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    16x bolts, 10mm, 6 Nm
  11. Position oil drain container under RDU drain valve
  12. Remove fill plug from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x plug, 8mm allen, 15 Nm
  13. Disconnect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  14. Remove fasteners securing RDU oil pump
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 5 Nm and 20 degrees
  15. Remove RDU oil pump assembly
    Informational PurposesAn informational icon, calling your attention
    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
  16. Remove RDU oil filter
    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.
  17. Inspect seals and O-rings
    Informational PurposesAn informational icon, calling your attention
    Note
    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
  18. Install new RDU oil filter
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Spin clockwise, 3 Nm and 135 degrees, Lubricate seal prior to installation
  19. Install RDU oil pump assembly
    Informational PurposesAn informational icon, calling your attention
    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
  20. Install fasteners securing RDU oil pump
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 5 Nm and 20 degrees
  21. Set up fill kit with KAF1 gearbox fluid.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fill measuring container to 2.3L / 2300 mL - Long range rear drive unit will take 2.1L of fluid
  22. Install fluid transfer pump
    Informational PurposesAn informational icon, calling your attention
    Note
    Trim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm
  23. Set up fill process
    Informational PurposesAn informational icon, calling your attention
    Note
    Place measured fluid container in drain basket, Fully submerge input hose, Prime pump with drive unit fluid
  24. Connect 12V power supply to RDU oil pump
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  25. Pump fluid into rear drive unit
    Informational PurposesAn informational icon, calling your attention
    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
  26. Install fill plug onto RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x plug, 8mm Allen, 15 Nm,
  27. Disconnect 12V power supply from RDU oil pump
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  28. Connect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  29. Spray area with brake cleaner and wipe residual fluid off with towel
  30. Remove oil drain container from underneath vehicle
  31. Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    16x bolts, 10mm, 6 Nm
  32. Install clips securing mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  33. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  34. Connect First Responder Loop and LV battery connector
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
  35. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  36. Release IP service panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 4x datums, Release top tabs and slide rearward
  37. Using laptop connect to vehicle with ethernet diag kit and Toolbox 3
    Informational PurposesAn informational icon, calling your attention
    Note
    Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, For local connection issues with Toolbox 3 refer to article #43695, Media converter box is powered by laptop USB or 12v power outlet, Ethernet connection will provide communication
  38. Select "Actions" tab and search for "Service-Redeploy"
  39. Select "SERVICE CAN REDEPLOY", click "Run", and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select "X" at top right of window to close once complete, Routine will state pass but update will continue to run in the background, UI will show update progress
  40. Select the clock on the center display, or go to the Software tab, then select install now to start firmware update
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Install Now, Tap count down timer until clock runs down to 0, Check the center display and ensure the firmware package was successfully installed
  41. Select "Actions/Autodiag" tab and search for "Oil Pressure"
  42. Select TEST-SELF_DIR_X_OIL-PUMPSearch for routine in ToolboxOil Pump Communication Test - Rear-PRESSURE, click "Run", and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    If this test is failing, add additional fluid and retest. Select "X" at top right of window to close once complete
  43. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit
  44. Install IP service panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP
  45. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
  46. Raise LH front window
  47. Close LH front door