2024-05-23

Drive Unit - Rear (Plaid) (Remove and Replace)

Correction code 40016102 3.60 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

  • 2024-02-06: Updated gearbox fluid.
  • 2024-01-24: Added a note to install a new motor ID label in hood/trunk for China, Japan and Korea.
  • 2023-05-02: Updated to latest validation.
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.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Do not drain the gearbox fluid from the removed drive unit. Return the drive unit to MRB with the fluid intact for analysis. Transfer the halfshaft caps from the new drive unit to the removed drive unit to prevent spillage.

Remove

  1. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  3. Perform a thermal fluid fill/drain. See Thermal Fluid - Cooling System (Fill/Drain).
  4. Release the electronic parking brake. See Park Brake Caliper - Release.
  5. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Disconnect LV power. See LV Power (Disconnect and Connect).
  8. Set the high voltage multimeter to DC voltage, lightly touch the probes to the auxiliary battery connector contacts, and verify that the multimeter displays a voltage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Battery voltage is typically 14.5 to 15.5 volts.
  9. Remove the rear wheels. See Wheel Assembly (Remove and Install).
  10. Remove the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  11. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  12. Remove the leather glove protectors and HV insulating gloves.
  13. Remove the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  14. Remove the LH and RH rear wheel arch liners. See Wheel Arch Liner - Rear - LH (Remove and Replace).
  15. Remove the rear subframe assembly. See Subframe Assembly - Rear (Plaid) (Remove and Install).
  16. Remove the bolt and release the clip that attach the ground strap to the rear drive unit and rear subframe, and then remove the ground strap from the subframe.
  17. Remove the bolt that attaches the LH ride height sensor arm to the LH upper fore link.
  18. Disconnect the electrical harness from the LH ride height sensor connector, and then release the clip that attaches the electrical harness to the rear drive unit.
  19. Remove the bolts (x2) that attach the LH upper aft link to the rear subframe.
  20. Remove the bolts (x2) that attach the LH upper fore link to the rear subframe.
  21. Remove the bolts (x2) that attach the LH toe link to the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the knuckle while removing.
  22. Install the axle removal tool around the inner joint of the LH rear halfshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the cable loop is not wrapped around the inner boot.
  23. Use the slide hammer to release the LH rear halfshaft from the rear drive unit.
  24. Repeat step 17 through step 23 for the RH side of the vehicle.
  25. Remove the bolts (x4) that attach the rear subframe brace to the rear subframe, and then remove the brace from the subframe.
  26. Release the clips (x2), disconnect the powertrain coolant supply hose fittings from the rear drive unit LH and RH inverters, and then immediately plug the fittings for the LH and RH branches of the powertrain coolant supply hose and the LH and RH inverters.
  27. Release the clips (x9) that attach the powertrain coolant supply hose to the rear drive unit, and then remove the hose from the drive unit.
  28. Release the clips (x2), disconnect the powertrain coolant return hose fittings from the rear drive unit LH and RH heat exchangers, and then immediately plug the fittings for the LH and RH branches of the powertrain coolant return hose and the LH and RH heat exchangers.
  29. Release the clips (x3) that attach the powertrain coolant return hose to the rear drive unit, and then remove the hose from the drive unit.
  30. Release the clips (x2), disconnect the LH inverter to LH heat exchanger hose fittings from the rear drive unit LH inverter and rear drive unit LH heat exchanger, and then immediately plug the fittings of the hose, inverter, and heat exchanger.
  31. Release the clips (x4) that attach the LH inverter to LH heat exchanger hose to the rear drive unit, and then remove the hose from the drive unit.
  32. Release the clips (x2), disconnect the RH inverter to RH heat exchanger hose fittings from the rear drive unit RH inverter and rear drive unit RH heat exchanger, and then immediately plug the fittings of the hose, inverter, and heat exchanger.
  33. Release the clips (x4) that attach the RH inverter to RH heat exchanger hose to the rear drive unit, and then remove the hose from the drive unit.
  34. Position the subframe lift underneath the gantry.
  35. Install an additional shackle to the blue and red cables, and then use the hooks (x3) to attach the drive unit sling tool to the rear drive unit.
  36. Attach the drive unit sling tool to the gantry.
  37. Use the gantry to raise the drive unit sling tool so that there is slight tension in the cables.
  38. Remove the bolt that attaches the rear drive unit to the LH side of the rear subframe.
  39. Remove the bolt that attaches the rear drive unit to the RH side of the rear subframe.
  40. Remove the bolt that attaches the rear drive unit to the rear of the rear subframe.
  41. 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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not fully remove the drive unit from the rear subframe as the HV harnesses are still attached.
  42. Slide the red connector locking tab, open the black release lever, and then disconnect the rear drive unit LH HV harness from the LH inverter of the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Repeat for the rear drive unit RH HV harness.
  43. Remove the bolts (x2) that attach the rear drive unit HV harnesses to the rear drive unit, and then remove the HV harnesses from the drive unit.
  44. Move the rear subframe and subframe lift out from underneath the rear drive unit.
  45. Perform a diode test on the rear drive unit LH and RH inverters. See Drive Unit Inverter Diode Test.
  46. Position the empty rear drive unit crate underneath the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pallet if no empty crate is available.
  47. Lower the rear drive unit into the rear drive unit crate.
  48. Remove the drive unit sling tool from the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Keep the extra shackles on the blue and red cables.

Install

  1. Position the new rear drive unit underneath the gantry.
  2. Use the hooks (x3) to attach the drive unit sling tool to the new rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    New drive unit comes prefilled with gearbox fluid.
  3. Raise the rear drive unit out of the rear drive unit crate.
  4. Move the rear subframe and subframe lift to underneath the rear drive unit.
  5. With the help of an assistant, use the gantry to lower the rear drive unit sling tool, guide halfshafts away from the rear drive unit, and position the rear drive unit just above the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not fully lower the rear drive unit as it might damage the HV harnesses.
  6. Install the rear drive unit LH and RH HV harnesses to the rear drive unit, and then install the bolts (x2) that attach the rear drive unit HV harnesses to the rear drive unit.
    6 Nm (4.4 lbs-ft)
  7. Verify that the black release lever of the rear drive unit LH HV harness connector is in the open position, install the connector flat and square to the rear drive unit LH inverter HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
    Informational PurposesAn informational icon, calling your attention
    Note
    Repeat for the rear drive unit RH HV harness.
  8. 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.
  9. Install and hand tighten the bolt that attaches the rear drive unit to the RH side of the rear subframe.
  10. Install and hand tighten the bolt that attaches the rear drive unit to the LH side of the rear subframe.
  11. Lower the drive unit sling tool to release tension in the cables, and then remove the sling tool from the gantry.
  12. Remove the hooks (x3), and then remove the drive unit sling tool from the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the extra shackles on the blue and red cables.
  13. Tighten the rear drive unit mount bolts (x3).
    120 Nm (88.5 lbs-ft)
    213 Nm (157.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque E18 120 Nm, torque EP20 213 Nm.
  14. Install the RH inverter to RH heat exchanger hose to the rear drive unit, and then fasten the clips (x4) that attach the hose to the drive unit.
  15. Remove the plugs from the fittings, immediately connect the RH inverter to RH heat exchanger hose to the rear drive unit RH inverter and rear drive unit RH heat exchanger, and then fasten the clips (x2) that secure the fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test at the fittings to make sure the hose is securely connected.
  16. Install the LH inverter to LH heat exchanger hose to the rear drive unit, and then fasten the clips (x4) that attach the hose to the drive unit.
  17. Remove the plugs from the fittings, immediately connect the LH inverter to LH heat exchanger hose to the rear drive unit LH inverter and rear drive unit LH heat exchanger, and then fasten the clips (x2) that secure the fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test at the fittings to make sure the hose is securely connected.
  18. Install the powertrain coolant return hose to the rear drive unit, and then fasten the clips (x3) that attach the hose to the drive unit.
  19. Remove the plugs from the fittings, immediately connect the LH and RH branches of the powertrain coolant return hose to the rear drive unit LH and RH heat exchangers, and then fasten the clips (x2) that secure the fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test at the fittings to make sure the hose is securely connected.
  20. Install the powertrain coolant supply hose to the rear drive unit, and then fasten the clips (x9) that attach the hose to the drive unit.
  21. Remove the plugs from the fittings, immediately connect the LH and RH branches of the powertrain coolant supply hose to the rear drive unit LH and RH inverters, and then fasten the clips (x2) that secure the fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test at the fittings to make sure the hose is securely connected.
  22. Install the rear subframe brace to the rear subframe, and then install the bolts (x4) that attach the brace to the subframe.
    120 Nm (88.5 lbs-ft)
  23. Loosen the nut and bolt that attach the LH toe link to the LH rear knuckle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the nut or bolt.
  24. Loosen the nut and bolt that attach the LH upper fore link to the LH rear knuckle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the nut or bolt.
  25. Loosen the nut and bolt that attach the RH toe link to the RH rear knuckle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the nut or bolt.
  26. Loosen the nut and bolt that attach the RH upper fore link to the RH rear knuckle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the nut or bolt.
  27. Loosen the nut and bolts that attach the LH and RH upper aft links to the LH and RH rear knuckles.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the nut or bolt.
  28. Remove the axle seal plug, and with the help of an assistant, install the LH rear halfshaft into the rear drive unit, and then firmly press the halfshaft into the drive unit so that the halfshaft is fully seated.
    Informational PurposesAn informational icon, calling your attention
    Note
    An audible click is heard when the halfshaft is fully seated and the C-clip is fully engaged.
  29. Install the bolts (x2) that attach the LH toe link to the rear subframe.
    85 Nm (62.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the knuckle while installing.
  30. Install the bolts (x2) that attach the LH upper fore link to the rear subframe.
    85 Nm (62.7 lbs-ft)
  31. Install the bolts (x2) that attach the LH upper aft link to the rear subframe.
    85 Nm (62.7 lbs-ft)
  32. Fasten the clip that attaches the electrical harness to the rear drive unit, and then connect the electrical harness to the LH ride height sensor connector.
  33. Install the bolt that attaches the LH ride height sensor arm to the LH upper fore link.
    8 Nm (5.9 lbs-ft)
  34. Repeat step 28 through step 33 for the RH side of the vehicle.
  35. Install the ground strap to the rear drive unit and rear subframe, and then install the bolt and fasten the clip that attach the ground strap to the subframe.
    10 Nm (7.4 lbs-ft)
  36. Install the rear subframe assembly. See Subframe Assembly - Rear (Plaid) (Remove and Install).
  37. Install the LH and RH rear wheel arch liners. See Wheel Arch Liner - Rear - LH (Remove and Replace).
  38. Install the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  39. Install the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  40. Install the rear wheels. See Wheel Assembly (Remove and Install).
  41. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  42. Connect LV power. See LV Power (Disconnect and Connect).
  43. Engage the electronic parking brake. See Park Brake Caliper - Release.
  44. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  45. Perform a software redeploy. See Firmware Reinstall - Toolbox.
  46. Perform a cooling system air purge. See Cooling System (Partial Refill and Bleed).
  47. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  48. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  49. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  50. For China, Japan and Korea only: Carefully remove the old motor label from the hood, and install a new motor label to match the new motor information.