Hydraulic Control Unit (HCU) - Brake (Remove and Replace)
Correction code 33109522 2.70 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.
Remove
- Open the LH front door and lower the LH front window.
- Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
- Remove all wheels. See Wheel Assembly (Remove and Install).
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Disconnect LV power. See LV Power (Disconnect and Connect).
- Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
- Remove the LH and RH wiper arms. See Wiper Arm - LH (Remove and Replace).
- Remove the LH and RH shock tower covers. See .
- Remove the wiper cowl screen panel. See .
-
Remove the bolts (x3) that attach the
LV battery, and then move the LV battery aside.Tip: Use of the following tool(s) is recommended:
- 10 mm ratcheting combination wrench
- 10 mm socket
NoteTake note of the datums and carefully move the LV battery aside. - Remove the LH shock tower V-brace. See V Brace - Shock Tower - LH (Remove and Replace).
-
Clean the area around the brake fluid
reservoir, and then remove the brake reservoir cap.
-
Remove brake fluid from the brake
reservoir using the measure and fill kit (1541474-00-B).
-
Install the brake reservoir cap.
-
Disconnect the air quality sensor
electrical connector.
-
Remove the HEPA filter assembly
cover.
NoteTabs (x2), datums (x2), slots (x2)CAUTIONDo not damage the mounting clips. Maneuver the cover forward and up in front of the V-brace cross member.
- Remove the battery controller module. See Module - Battery Controller (Remove and Replace).
- Remove the LH front wheel arch liner. See .
-
Disconnect the LH front repeater
electrical connectors (x2).
-
Release the clip that attaches the LH
repeater electrical harness to the body.
-
Disconnect the LH front ride height
sensor electrical connector.
-
Disconnect the ground junction
connector G500.
NoteRelease the red locking tab. Press the black tab and rotate the lever to release it.
-
Remove the bolt that attaches the
junction ground terminal to the body.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Push the LH wheelwell section of the
front main harness through the body into the frunk.
-
Remove the bolts (x3) that attach the
Hydraulic Control Unit (HCU) bracket to the vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
- Torx T40 socket
NoteThe bolt location may vary in early production models. - Place shop rags beneath the brake lines to catch any fluid lost.
-
Disconnect the brake fluid level
sensor electrical connector.
-
Disconnect the brake lines (x2) from
the master cylinder.Tip: Use of the following tool(s) is recommended:
- 12 mm ratcheting combination wrench
-
Remove the 4-tube bundle brake lines
from the HCU.Tip: Use of the following tool(s) is recommended:
- 12 mm ratcheting combination wrench
-
Disconnect the electrical connector
from the HCU.
NoteRelease the red locking tab and rotate the lever upward to disconnect.
-
Apply tape to the HCU harness
connector to prevent brake fluid leaking into the connector.
-
Release the clips (x2) that attach the
brake lines to the bottom of the HCU bundle.
-
Release the clips (x2) that attach the
brake lines to the LH side of HCU bundle.
Tip: Support the HCU with one hand while using side the access hole to release the lines.
-
Remove the HCU, bracket and brake
lines from vehicle as an assembly.
NoteRotate and lift assembly up along the brake booster while shifting 4-tube brake lines aside.CAUTIONDo not bend the brake lines.
-
Remove the master cylinder brake lines
(x2) from the HCU.Tip: Use of the following tool(s) is recommended:
- 12 mm ratcheting combination wrench
-
Loosen the nuts that attach the HCU to
the HCU bracket.
Tip: The nuts do not need to be fully removed because the bracket is slotted.
-
Remove the pin that attaches the HCU
to the HCU bracket.
Tip: Pry between bracket and HCU to release the pin.
Install
-
Position the HCU to the HCU
bracket.
NoteAlign the bracket to the rubber bushings and press together to attach the snapfit pin.
-
Tighten the nuts (x2) that attach the
HCU to the HCU bracket.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Peel back the protective tape, and
then install the master cylinder brake lines (x2) to the HCU.Tip: Use of the following tool(s) is recommended:
- 12 mm ratcheting combination wrench
- 12 mm open crowfoot socket
NoteLeave the tape covering the 4-tube outlets to prevent contamination during installation. -
Install the HCU assembly to the
vehicle.
NoteRotate and lower the assembly down along the brake booster while shifting 4-tube brake lines over.CAUTIONDo not bend the brake lines.
-
Position the clips (x2) that attach
the brake lines to LH side of the HCU bundle.
Tip: Support the HCU with one hand while using side the access hole to attach the brake lines to the clips.
-
Attach the brake lines (x2) to the
bottom of the HCU bundle.
- Remove the tape from the HCU harness connector.
-
Connect the HCU electrical
connector.
NoteSeat the connection and rotate the lever downward, then insert the red locking tab.
-
Remove the remaining protective tape
and install the 4-tube bundle brake lines to the HCU.Tip: Use of the following tool(s) is recommended:
- 12 mm ratcheting combination wrench
- 12 mm open crowfoot socket
Tip: Clean the threads of the brake lines with brake cleaner before mating. -
Install the brake lines to the master
cylinder.Tip: Use of the following tool(s) is recommended:
- 12 mm ratcheting combination wrench
- 12 mm open crowfoot socket
Tip: Clean the threads of the brake lines with brake cleaner before mating. -
Connect the brake fluid level sensor
electrical connector.
- Remove the shop rags from beneath the brake lines, and then clean up any residual fluid lost.
-
Install the bolts (x3) that attach the
HCU bracket.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
- Torx T40 socket
NoteHand start the bolts to prevent cross-threading.NoteThe bolt location may vary in early production models. -
Route the LH wheelwell section of the
front main harness through the body.
-
Install the bolt that attaches the
junction ground terminal to the body.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Connect the ground junction connector
G500.
NoteSecure the red locking tab.
-
Connect the LH front ride height
sensor electrical connector.
-
Insert the clip that attaches the LH
repeater harness to the body.
-
Connect the electrical connectors (x2)
to the LH front repeater.
NoteSupport the repeater from exterior to prevent damage to the retaining clips.
- Install the LH front wheel arch liner. See .
- Install the battery controller module. See Module - Battery Controller (Remove and Replace).
- Install the HEPA filter assembly cover. See Filter - HEPA (Remove and Replace).
- Install the LH shock tower V-brace. See V Brace - Shock Tower - LH (Remove and Replace).
- Install the cowl screen panel. See .
- Install the LV battery. See Battery - LV (Remove and Replace).
- Install the LH and RH wiper arms. See Wiper Arm - LH (Remove and Replace).
- Install the LH and RH shock tower covers. See .
- Connect LV power. See LV Power (Disconnect and Connect).
- Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
- Perform a firmware reinstall. See Firmware Reinstall - Toolbox.
- Perform a brake fluid flush. See Brake Fluid Bleed/Flush (Remove and Replace).
- Disconnect the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).
- Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Install all wheels. See Wheel Assembly (Remove and Install).
- Perform a vehicle road test. Make sure proper brake pedal feel and performance is achieved.