25/06/2024 07:41:50

Drive Unit - Front (Remove and Install)

Correction code 39013101 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.

  • 2024-06-25: Added special tool list to procedure.
  • 2023-08-02: Added steps to disconnect frunk harness from front drive unit connector and remove ground strap.

Special tools required for this procedure:

Part Number Description
1754057-00-A CURRENT PROBE, GEN, CLAMP, DC, 600V
1066521-00-A OTC POWERTRAIN LIFT 1,650lb
1096075-00-A TOOL, HUB PULLER, HYDRAULIC
1498673-00-A KIT, CABLE AXLE REMOVER, MS/MX/M3
1140311-00-A LEVER LOCK, HV CONNECTOR, MODEL 3
1965406-00-A TORQUE WRENCH, DIGITAL+ANGLE, 3/8" DR, FLEX HEAD, 13.5~135Nm
1050448-00-B VACUUM REFILL TOOL
1657054-00-A SUBFRAME FIXTURE, PALLADIUM
1135762-00-A KIT, SVC PLUG, COOLING HOSE, MODEL 3
1020566-00-G ASY, BATTERY TABLE, MANUAL LIFT
1053589-00-A SLIDE HAMMER, 3 JAW
1063141-00-A TRANSMISSION JACK
1130279-00-A LIFTING SLING, DRIVE UNIT, MODEL 3
1065131-00-A KIT, BATTERY COOLANT DRAIN & FILL
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.
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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. Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
  3. Remove the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).
  4. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  5. Position the 2 post lift pads for HV battery removal.
  6. Set the steering wheel straight ahead, place a protector sheet onto the driver seat, and then install the steering wheel lock.
  7. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  8. Disconnect LV power. See LV Power (Disconnect and Connect).
  9. 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.
  10. Remove the bolt that attaches the ground strap to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt is captive to the ground strap.
  11. Pull the red tab, and then pull the tab again to disconnect the frunk harness from the front drive unit harness connector.
  12. Release the clip that attaches the frunk harness to the front drive unit.
  13. Loosen the LH and RH front axle nuts.
  14. Remove the LH and RH front wheels. See Wheel Assembly (Remove and Install).
  15. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  16. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  17. Remove the leather glove protectors and the HV insulating gloves.
  18. Remove the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  19. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  20. Remove the DC input HV header foam block.
  21. Remove the bolt that secures the charge port busbar connector access door.
  22. Remove the bolts (x2) that attach the charge port busbar connector to the DC input HV header.
    9 Nm (6.6 lbs-ft)
  23. Lift the charge port busbar connector to remove the connector from the DC input HV header.
  24. Remove the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  25. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  26. Remove the front skid plate. See Skidplate - Front (Remove and Replace).
  27. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  28. Remove the front fascia valance. See Valance - Front Fascia (Remove and Replace).
  29. Remove the front subframe. See Subframe Assembly - Front (Remove and Install).
  30. Remove the LH and RH front halfshafts. See Halfshaft - Front Drive Unit - LH (Remove and Replace) and Halfshaft - Front Drive Unit - RH (Remove and Replace).
  31. Move the coolant drain container to under the front drive unit.
  32. Release the clip, disconnect the powertrain coolant return hose from the front drive unit heat exchanger, and then immediately plug the fittings for the hose and heat exchanger.
  33. Release the clip, disconnect the powertrain coolant hose from the front drive unit inverter hose, and then immediately plug the fittings.
  34. Move the coolant drain container out from underneath the vehicle.
  35. Release the clips (x3) that attach the electrical harness and HVAC drain tube to the RH front frame rail.
  36. Release the clips (x2) that attach the electrical harness and HVAC drain tube to the RH cross brace, remove the bolts (x3) that attach the cross brace to the RH casting, and then remove the cross brace from the vehicle.
  37. Remove the bolts (x3) that attach the LH cross brace to the LH casting, and then remove the cross brace from the vehicle.
  38. Position a transmission jack fixture under the front drive unit.
  39. Raise the transmission jack fixture up and against the front drive unit, and then use the strap to secure the drive unit to the fixture.
  40. Remove the bolts (x2) that attach the LH front drive unit mount to the LH casting.
  41. Remove the bolts (x2) that attach the RH front drive unit mount to the RH casting.
  42. With the help of an assistant, lower the transmission jack fixture, and maneuver harnesses and hoses around the front drive unit as it is lowered.
  43. Move the transmission jack fixture out from under the vehicle.

Install

  1. Move the transmission jack fixture under the vehicle.
  2. With the help of an assistant, raise the transmission jack fixture, and maneuver harnesses and hoses around the front drive unit as it is raised into position.
  3. Install and hand tighten the bolts (x2) that attach the LH front drive unit mount to the LH casting.
  4. Raise the transmission jack fixture more to align the RH front drive unit mount with the RH casting.
  5. Install and hand tighten the bolts (x2) that attach the RH front drive unit mount to the RH casting.
  6. Tighten the bolt that attaches the rear of the RH front drive unit mount to the RH casting.
    120 Nm (88.5 lbs-ft)
  7. Tighten the bolt that attaches the rear of the RH front drive unit mount to the RH casting.
    120 Nm (88.5 lbs-ft)
  8. Tighten the bolts (x2) that attach the LH front drive unit mount to the LH casting.
    65 Nm (47.9 lbs-ft)
  9. Releae the strap and lower the transmission jack fixture from the front drive unit.
  10. Move the transmission jack fixture out from under the front drive unit.
  11. Install the LH cross brace to the LH casting, and then install the bolts (x3) that attach the cross brace to the casting.
    30 Nm (22.1 lbs-ft)
  12. Install the RH cross brace to the RH casting, install the bolts (x3) that attach the cross brack to the casting, and then fasten the clips (x2) that attach the electrical harness and HVAC drain tube to the cross brace.
    30 Nm (22.1 lbs-ft)
  13. Fasten the clips (x3) that attach the electrical harness and HVAC drain tube to the RH front frame rail.
  14. Move the coolant drain container to under the front drive unit.
  15. Remove the plugs from the fittings, immediately connect the powertrain coolant hose to the front drive unit inverter hose, and then fasten the clip that secures the fittings.
  16. Remove the plugs from the fittings, immediately connect the powertrain coolant return hose to the front drive unit heat exchanger, and then fasten the clip that secures the fittings.
  17. Move the coolant drain container out from underneath the vehicle.
  18. Install the LH and RH front halfshafts. See Halfshaft - Front Drive Unit - LH (Remove and Replace) and Halfshaft - Front Drive Unit - RH (Remove and Replace).
  19. Install the front subframe. See Subframe Assembly - Front (Remove and Install).
  20. Install the front fascia valance. See Valance - Front Fascia (Remove and Replace).
  21. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  22. Install the front skid plate. See Skidplate - Front (Remove and Replace).
  23. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  24. Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  25. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  26. Install the LH and RH front wheels. See Wheel Assembly (Remove and Install).
  27. Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.
  28. Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.
  29. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.
  30. Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.
    9 Nm (6.6 lbs-ft)
  31. Put on the HV insulating gloves and leather over gloves.
  32. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  33. Repeat step 32 for the other charge port busbar connector lead and DC input HV header bolt head.
  34. Remove the HV insulating gloves and leather over gloves.
  35. Install the bolt that secures the charge port busbar connector access door.
    9 Nm (6.6 lbs-ft)
  36. Install the DC input HV header foam block.
  37. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  38. Install the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  39. Tighten the LH and RH front axle nuts.
    245 Nm (180.7 lbs-ft)
  40. Fasten the clip that attaches the frunk harness to the front drive unit.
  41. Connect the frunk harness to the front drive unit harness connector, and then push in the red tab to secure.
  42. Install the bolt that attaches the ground strap to the front drive unit.
    5.5 Nm (4.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt is captive to the ground strap.
  43. Remove the steering wheel lock, and then remove the protector sheet from the driver seat.
  44. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  45. Connect LV power. See LV Power (Disconnect and Connect).
  46. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  47. Perform a cooling system air purge. See Cooling System (Partial Refill and Bleed).
  48. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  49. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  50. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  51. Install the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).
  52. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  53. Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.