01/04/2024 14:01:58

Heat Exchanger - Front Drive Unit (Remove and Replace)

Correction code 39301002 1.20 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

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.

Raise and support vehicle

Note
Set air suspension to "Jack Mode"
Open hood

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Using center display touchscreen > Quick Controls > Frunk Open
Remove rear underhood apron

Note
8x clips
Power off vehicle from center display

Note
Via Controls > Safety & Security > Power Off
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection
Raise vehicle fully and lower lift onto locks
Remove clips securing front aero shield

Note
5x push clips
Remove bolts securing front aero shield and remove from vehicle

Note
9x bolts, 10mm, 6 Nm
Release clips securing wheel house liner to front skid plate

Note
4x clips
Remove bolts securing front skid plate to body sill

Note
2x bolts, 15mm, 30 Nm
Remove bolts securing front skid plate to body casting

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2x bolts, 15mm, 60 Nm
Remove bolts securing front skid plate to front subframe and remove skid plate

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm
Disconnect the FDU oil pump connector

Note
1x electrical connector, Disengage locking tab, then release connector
Release the indicated inverter coolant hose clips from FDU

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2x clips
Release front oil pump harness clip from heat exchanger

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1x clip
Position foldable funnel under front drive unit

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Prevent coolant contamination to HV battery components
Position coolant drain container under the front of the vehicle to catch vehicle coolant
Release powertrain return hose from heat exchanger

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1x hose clip, Plug both ends, Allow any excess fluid to drain
Release FDU inverter hose from heat exchanger

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1x hose clip, Plug both ends as needed,
Remove foldable funnel from subframe
Release bolts securing FDU heat exchanger

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2x bolts, EP10, 5 Nm + 30 degrees
Remove FDU heat exchanger

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2x O-rings
Install FDU heat exchanger

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 FDU oil passages, Prevent cross-contamination.
Install bolts securing heat exchanger to FDU

Note
2x bolts, EP10, 5 Nm + 30 degrees,
Secure FDU inverter hose onto heat exchanger

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1x hose clip, Remove any plugs, Perform push-pull-push test
Secure powertrain return hose onto heat exchanger

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1x hose clip, Remove any plugs, Perform push-pull-push test
Secure front oil pump harness clip onto heat exchanger

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1x clip
Secure coolant hose clip onto heat exchanger

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2x clips
Remove coolant drain container from underneath vehicle
Position foldable funnel under oil filter
Position the oil drain under oil pump area
Remove bolts securing oil pump to the FDU

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2x bolts, EP10, 5 Nm + 20 degrees
Remove oil pump from FDU

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Pry the pump away from the FDU with a pry tool or flat blade screwdriver on both tabs, Ensure the FDU casting is not damaged, Allow the oil to drain from the FDU
Remove oil filter from FDU

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 counterclockwise, 3 Nm and 135 degrees, Allow oil to drain
Remove fill plug from FDU

Note
1x plug, 8mm Allen, 15 Nm
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
Install new oil filter

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.

Note
Spin clockwise, 3 Nm and 135 degrees, Lubricate 3 seals prior to installation
Remove foldable funnel from subframe
Install oil pump into FDU

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Use residual oil in the oil pump cavity to lubricate the seals of the oil pump before installation, Align bolt holes with housing
Install bolts securing oil pump to FDU

Note
2x bolts, EP10, 5 Nm + 20 degrees
Set up fill kit with KAF1 fluid

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Set fluid level to 2.0L / 2000 mL in measuring container, Front drive unit will only take 1.8L
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
Set up fill process

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Place measured fluid container in drain basket, fully submerge input hose, prime pump with KAF1 fluid
Connect 12V power supply to oil pump

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1x connector
Pump KAF1 fluid into FDU

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Assistant required, Pump 5 full strokes from fluid container, then run pump via switch box for entire fill and keep running until drain plug installed, Do not run pump when dry, If pump is not running and drain plug not installed fluid will drain from plug within 10 seconds, Pump in 1.8L of fluid, Leftover fluid should be less that 200 mL
Install fill plug into the FDU

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1x plug, 8mm Allen, 15 Nm
Disconnect 12V power supply tool from oil pump

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1x electrical connector
Connect the oil pump connector

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1x electrical connector, Fully seat connector, then engage locking tab
Spray area with brake cleaner and wipe residual fluid off with towel
Remove oil drain container
Position front skid plate for installation and thread in all bolts

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 15mm, 60 Nm, 2x bolts, 15mm, 30 Nm, 2x bolts, 10mm, 10 Nm, Torque at later step
Torque bolts securing front skid plate to body casting

Note
2x bolts, 15mm, 60 Nm
Torque bolts securing front skid plate to body sill

Note
2x bolts, 15mm, 30 Nm
Torque bolts securing front skid plate to front subframe

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm
Secure clips securing wheel house liner to front skid plate

Note
4x clips
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle

Note
9x bolts, 10mm, 6 Nm
Install clips securing front aero shield

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5x push clips
Lower vehicle fully

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Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Remove coolant bottle cap
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
Connect First Responder Loop and LV battery connector

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
Release IP service panel

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2x tabs, 4x datums, Release top tabs and slide rearward
Using laptop connect to vehicle with ethernet diag kit and Toolbox 3

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
Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE ’, click ‘Run’, and allow routine to complete_x000A__x000A_

Note
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
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Install coolant bottle cap
Install rear underhood apron

Note
8x clips
Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit
Install IP service panel

Note
2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP

Model S Service Manual

Heat Exchanger - Front Drive Unit (Remove and Replace)

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