01/04/2024 14:01:48

Gearbox Fluid - Rear Drive Unit (Drain and Refill)

Correction code 40300102 0.48 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.
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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.

Procedure

  1. Raise and support vehicle.
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    Note
    Set air suspension to "Jack Mode" if equipped.
  2. Open hood.
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    Note
    Using center display touchscreen > Quick Controls > Frunk Open.
  3. Remove rear underhood apron.
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    Note
    8x clips.
  4. Power off vehicle from center display.
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    Note
    Via Controls > Safety & Security > Power Off.
  5. Disconnect LV battery connector and First Responder Loop.
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    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection.
  6. Raise vehicle fully and lower lift onto locks.
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    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.
  7. Remove clips securing mid aero shield.
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    Note
    4x push clips.
  8. Remove bolts securing mid aero shield and remove from vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  9. Position the oil drain under RDU oil filter area.
  10. Remove fill plug from RDU.
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    Note
    1x plug, 8mm Allen, 15 Nm.
  11. Disconnect oil pump connector.
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    Note
    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector.
  12. Remove fasteners from RDU oil pump.
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    Note
    2x bolts, EPL10, 5 Nm + 20 degrees.
  13. Remove the oil pump from the RDU.
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    Note
    Pry the pump away from the RDU, Be cautious when prying to avoid damage to plastic and casting, Allow the oil to drain from the RDU.
  14. Remove the oil filter from RDU.
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    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.
  15. Inspect seals and o-rings.
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    Note
    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.
  16. Install new RDU oil filter.
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    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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    Note
    Spin clockwise, 3 Nm + 135 degrees Lubricate seal prior to installation.
  17. Reinstall RDU oil pump assembly.
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    Note
    Make sure O-rings are lubricated prior to installation, .
  18. Install RDU oil pump fasteners.
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    Note
    2x bolts, EPL10, 5 Nm and 20 degrees.
  19. Set up fill kit with KAF1.
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    Note
    Fill measuring container to 2.3 liters/2300 mL.
  20. Install fluid transfer pump.
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    Note
    Trim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm.
  21. Set up fill process.
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    Note
    Place measured fluid container in drain basket, fully submerge input hose, prime pump with KAF1 fluid.
  22. Connect the 12V power supply to RDU oil pump.
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    Note
    1x connector.
  23. Recommend assistance for following steps as they are critical to properly fill RDU to spec.
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    Note
    Assistant will run oil pump switchbox using XP-10 Jump Pack and have RDU fill plug ready for installation.
  24. Pump KAF1 fluid into rear drive unit.
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    Note
    Assistant required, Do not run pump dry, Pump 5 full strokes from fluid container before running pump. Run oil pump switch box for entire fill process. Keep running oil pump switch box until drain plug is installed in next step, If pump is not running and drain plug is not installed fluid will drain from plug within 10 seconds. Note: The minimum refill capacity of the rear drive unit assembly is 2.1 liters. Using excess gearbox fluid in the fill container allows the oil pump to dispense the full 2.1L without drawing air. Make sure that there is less than 200mL left when completed. Pumping the full 2.3 liters is not required.
  25. Continue running oil pump switch box, Remove hand pump from fill hole and Install fill plug into RDU.
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    Note
    1x plug, 8mm Allen, 15 Nm, Assistance required, The switch box should continue to be ran until the system is closed.
  26. Disconnect 12V power supply tool from oil pump.
  27. Connect oil pump connector.
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    Note
    1x connector, Engage locking tab.
  28. Spray area with brake cleaner and wipe residual fluid off with towel.
  29. Remove the oil drain container from underneath rear drive unit.
  30. Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  31. Install clips securing mid aero shield.
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    Note
    4x push clips.
  32. Lower vehicle fully.
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  33. Connect First Responder Loop and LV battery connector.
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    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.
  34. Install rear underhood apron.
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    Note
    8x clips.
  35. Using laptop connect to vehicle with ethernet diag kit and Toolbox 3.
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    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 using USB, Ethernet connection will provide communication.
  36. Select Actions/Autodiag tab and search for "Oil Pressure".
  37. Select TEST-SELF_DIR_X_OIL-PUMP-PRESSURESearch for routine in ToolboxOil Pump Low Pressure Test - Rear Drive Unit, click Run, and allow routine to complete.
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    Note
    If this test is failing, add additional fluid and retest. Select ‘X’ at top right of window to close once complete.
  38. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit.
  39. Remove vehicle from lift.
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    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".