04/06/2024 06:51:25

Halfshaft - Rear Drive Unit - LH (Remove and Replace)

Correction code 40302002 1.26 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.

2024-06-04: Updated EPB Service Mode reference.
2024-01-19: Updated EPB Service Mode reference.

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.

Open LH front door
Lower LH front window
Raise and support vehicle

Note
Set air suspension to "Jack Mode" if equipped
Place the vehicle into EPB Service Mode. See Park Brake Caliper - Release.
Remove LH rear wheel center cap

Note
1x cap
Loosen the LH rear axle nut

Note
1x nut, 32mm, 245 Nm
Remove LH rear wheel cap

Note
Lift every other spoke at a time until cap is released from rim
Loosen LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle partially and lower onto locks

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
Remove LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Disconnect EPB harness connector to the LH caliper motor

Note
1x connector, Disengage locking tab then release connector
Release subframe harness from LH rear active dampener

Note
2x connectors, 1x grommet
Release harness clip from LH rear knuckle

Note
1x clip
Remove wheel speed sensor from LH rear knuckle

Note
1x bolt, T30, 5 Nm
Release connector to LH rear ANC sensor

Note
1x connector, Disengage red locking tab and push down on black tab to release
Release subframe harness from LH lower control arm

Note
1x fur tree clip
Remove bolts securing LH rear knuckle harness bracket and move aside

Note
2x bolts, T30, 5 Nm, Move harness aside with bracket
Release LH rear brake hose from LH rear lower control arm

Note
1x bolt, 10mm, 6 Nm
Release LH rear stabar link from rear knuckle assembly

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove LH rear brake caliper from LH rear knuckle and hang from body

Note
2x bolts, E18, 125 Nm, Route caliper hose so that it does not get caught on stabar assembly
Remove axle nut and discard washer securing LH rear drive axle to hub assembly

Note
If washers are not present, procure a set so they can be installed later in this procedure.

Note
1x nut, 32mm, 245 Nm
If installed, remove and discard the bolt that attaches the brake rotor to the hub.
Note
A new bolt will not be installed.
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Install the hub puller onto the LH rear brake rotor

Note
5x lug nuts, 21mm, Hand tight
Use hub puller to free LH rear halfshaft from hub splines
Remove hub puller from LH rear hub assembly

Note
5x lug nuts, 21mm, Hand tight
Remove rotor from LH rear knuckle
Remove nut securing LH rear air spring module to LH rear knuckle

Note
1x nut, 21mm, 140 Nm, Do not remove the bolt
Remove bolt securing LH rear upper fore link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm
Remove bolt securing LH rear toe link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm
Remove bolt securing LH rear lower fore link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm
Remove bolt securing LH rear upper aft link to knuckle

Note
1x bolt, 21mm, 150 Nm
Remove bolt securing LH rear lower aft link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm
Remove LH rear knuckle assembly from vehicle

Note
Recommend assistance, Support knuckle as needed, Remove bolt holding knuckle to air strut and remove knuckle assembly
Release LH inboard CV joint from RDU and remove from vehicle

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
Position halfshaft into vehicle for installation

Note
Ensure snap-ring is installed on halfshaft assembly_x000A_
Install LH inboard CV joint into RDU

Note
Recommend assistance, Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Carefully push the halfshaft into the drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft
Apply Molykote M-77 to outboard side of LH axle shaft

Note
Clean if necessary, Apply no more than 1 gram to axle only
Position LH rear knuckle for installation

Note
Recommend assistance, Place knuckle into vehicle for installation, If required, use a bolt or punch to temporarily hold knuckle in place, Remove pin punch when fasteners for the links are ready to be installed
Align the splines of the LH rear halfshaft with those of the LH rear hub, and then install the halfshaft into the hub.
Install only the axle nut onto the halfshaft, and then use a ratchet and socket to manually tighten the nut to pull the halfshaft into the hub until it seats.

Note
Do not use power tools to tighten the nut as it might strip the threads.
Remove the axle nut from the halfshaft, install a new washer onto the halfshaft, and then reinstall the axle nut hand tightened.

Note
The axle nut is torqued in a later step.
Install bolt securing LH rear lower aft link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and secure flag nut, Torque at later step
Install bolt securing LH rear toe link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and secure flag nut, Torque at later step
Install bolt securing LH lower fore link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Use a pry bar to help align fastener hole to knuckle, Insert bolt and secure flag nut, Torque at later step
Install bolt securing LH upper fore link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and secure flag nut, Torque at later step
Install bolt securing LH rear upper aft link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and thread in fully, Torque at later step
Install bolt securing LH rear air spring module to LH rear knuckle

Note
1x bolt, 1x nut, 21mm, 150 Nm, Recommend assistance, Use shop towel and prevent marring on the air spring module, Line up air spring module with knuckle, Torque at later step
Position rotor onto LH rear knuckle
Install new axle nut and washer assembly

Note
1x nut, 32mm, 245 Nm, Install new fastener, Torque at later step
Install hub jack adapter onto LH rear hub

Note
5x lug nuts, 21mm, Hand tight, Used modified hydraulic hub tool if correct adapter is not available
Position and raise support stand to simulate LH rear suspension at ride height
Measure the distance from the upper fore link to the bolt on the frame rail to make sure LH suspension is set to ride height

Note
Distance should be 85mm +/- 5mm
Torque bolt securing LH rear toe link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Mark with paint pen
Torque bolt securing LH rear upper fore link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Mark with paint pen
Torque bolt securing LH rear lower aft link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Mark with paint pen
Torque bolt securing LH rear lower fore link to knuckle

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Mark with paint pen
Torque bolt securing LH rear upper aft link to knuckle

Note
1x bolt, 21mm, 150 Nm, Mark with paint pen
Torque bolt securing the LH shock to knuckle

Note
1x nut, 21mm, 150 Nm, Mark with paint pen
Remove support stand from underneath LH rear suspension

Note
Lower stand until suspension is unladen before removal
Remove hub jack adapter from LH rear hub

Note
5x lug nuts, 21mm, Hand tight
Install LH rear brake caliper to knuckle

Note
2x bolts, E18, 125 Nm, Remove S-hook
Secure LH rear brake hose to LH rear lower control arm

Note
1x bolt, 10mm, 6 Nm
Secure LH rear stabar link to rear knuckle assembly

Note
1x nyloc nut, 15mm, 55 Nm, Install new fastener,Counter-hold ball joint with 5mm hex
Route and install bolts securing LH rear knuckle harness bracket

Note
2x bolts, T30, 5 Nm, Route into place and secure
Secure subframe harness to LH lower aft arm

Note
1x clip
Secure connector to LH rear ANC sensor

Note
1x connector, Engage red locking tab
Install wheel speed sensor to LH rear knuckle

Note
1x bolt, T30, 5 Nm
Secure harness clip onto LH rear knuckle

Note
1x clip
Secure subframe harness to LH rear active dampener

Note
2x connectors, 1x grommet
Connect LH EPB caliper harness connector

Note
1x connector, Fully seat connector then engage locking tab
Install LH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque LH rear wheel

Note
5x nuts, 21 mm, 175 Nm
Install LH rear wheel cap

Note
Align valve stem with cap
Torque LH rear axle nut

Note
1x nut, 32mm, 245 Nm
Install LH rear wheel center cap

Note
1x cap, Verify emblem is aligned with valve stem
Hold brake pedal and select park on UI to disable EPB service mode
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Perform an alignment check. See Four Wheel Alignment Check.