26/07/2023 16:47:52

Subframe Assembly - Front (3rd Generation) (Remove and Install)

Correction Code 30010341

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1060616-00-B Wheel Nut Cover Removal Tool
Tesla 1135762-00-A Cooling Hose Plug Kit
Tesla 1027589-00-E Subframe Fixture
Tesla 1066521-00-A Powertrain Table

This procedure is for vehicles built after April 24, 2019.

For other generation front subframe assemblies, see also:

Remove

  1. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift .
  2. Point the steering wheel towards the center, and then install the steering wheel holder on the steering wheel and secure the steering wheel from turning.
  3. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  4. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  5. Remove the front underhood apron. See Underhood Apron - Front (Remove and Replace) .
  6. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  7. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  8. Remove the underhood storage carpet. See Carpet - Underhood Storage (Remove and Install) .
  9. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  10. Disconnect 12V power. See Disconnect 12V Power .
  11. Remove the bolts (x3) that attach the chiller assembly to the front subframe assembly.
  12. Release the battery pump 2 off the mounting bracket by sliding the pump to the right of the vehicle.
  13. Put an absorbent material such as a shop towel under the battery pump 2 hoses to absorb any residual coolant.
  14. Release the hose clamp that attaches the coolant hose from the 4-way valve to the battery pump 2, remove the hose from the pump, and then immediately plug both the pump and hose.
  15. Disconnect the steering rack electrical connectors (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Disengage the red locking tab before disconnecting the steering rack electrical connectors.
  16. Disconnect the electrical connectors (x2) for the steering rack logic.
  17. Release the clip that attaches the logic harness connector to the front subframe assembly.
  18. Remove the bolts (x2) that attach the air suspension pump bracket to the front subframe assembly.
  19. Secure the air suspension pump bracket and the chiller assembly to the front end carrier using bungee cords or similar tool.
  20. Loosen, but do not remove, the bolt that attaches the 3-way valve.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt will be removed at a later step in this procedure.
  21. Remove the LH and RH front lug nut covers from the front wheels using the wheel nut cover removal tool.
    Figure 1. LH wheel shown, RH wheel similar
  22. Remove the LH and RH front wheel center caps from the vehicles using the suction cup clamp tool.
  23. Loosen the LH and RH front axle nuts, but do not remove them yet (torque 245 Nm).
  24. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift .
  25. Remove the LH and RH front wheels.
  26. Remove and discard the RH nyloc nut that attaches the tie rod end to the steering knuckle, and then disconnect the tie rod from the steering knuckle. Repeat this step on the LH tie rod end.
    Figure 2. RH tie rod
    Figure 3. LH tie rod
  27. Remove the mid aero shield. See Panel - Aero Shield - Mid (Remove and Replace) .
  28. Remove the front extrusion bash plate. See Bash Plate - Front - Extrusion (Remove and Replace) .
  29. Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install) .
  30. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace) .
  31. Remove the front subframe skid bar. See Skid Bar - Front Subframe (Remove and Replace) .
  32. Remove the front bash plate stamping. See Bash Plate - Front - Stamping (Remove and Replace) .
  33. Remove the front skidplate. See Skidplate - Front (Remove and Replace) .
  34. Remove the bolt that attaches the RH front strut to the front lower aft link. Repeat this step on the LH front strut.
    Figure 4. RH side
    Figure 5. LH side
  35. Remove the bolt that attaches the LH front lower aft link to the front subframe assembly, and then move the link aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Index the location of the eccentric with a paint marker.
  36. Remove the bolt that attaches LH front lower fore link to the front subframe assembly, and then move the link aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Index the location of the eccentric with a paint marker.
  37. Remove the bolt that attaches the RH front lower aft link to the front subframe assembly, and then move the link aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Index the location of the eccentric with a paint marker.
  38. Remove the bolt that attaches the RH front lower fore link to the front subframe assembly, and then move the link aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Index the location of the eccentric with a paint marker.
  39. Remove and discard the nut that attaches the LH stabilizer bar to the stabilizer bar end link, and then remove the end link from the stabilizer bar. Repeat this step on the RH stabilizer bar.
    Figure 6. LH shown, RH similar
  40. Remove the bolt that attaches the lower i-shaft to the steering rack, and then slide the i-shaft up and away from the steering rack.
  41. Remove the forward bolt that attaches the RH 3-way valve to the subframe bracket.
  42. Remove the bolts (x2) that attach the LH stay bar to the front subframe assembly. Repeat this step on the RH stay bar.
  43. Remove the nuts (x2) that attach the ABS pump to the front subframe, and then release the ABS pump from the rubber mounting grommet.
  44. Put the coolant drain container under the LH corner of the vehicle to catch any coolant during the next step.
  45. Release the hose clamp that attaches the battery coolant heater-to-coolant pump 2 at the rear of the front subframe assembly, and then plug both ends using plugs from the coolant hose plug kit.
  46. Release the fir tree clips (x3) that attach the battery coolant heater-to-coolant pump 2 between the steering rack and the front subframe assembly.
  47. Move the coolant drain container to the RH corner of the vehicle to catch any coolant during the next step.
  48. Release the hose clip and the fir tree clip that attach the coolant hose from the radiator inlet, and then plug both ends using plugs from the coolant hose plug kit.
  49. Remove the coolant drain container from under the vehicle.
  50. Position the powertrain table with the Model S/X subframe adapter installed under the front of the vehicle.
  51. Connect shop air supply to the powertrain table.
  52. Raise the powertrain table and subframe fixture into position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the pins are installed into the correct positions on the fixture.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the pins engage the front subframe assembly so that it is properly supported.
  53. Remove and discard the bolts (x4) that attach the bumper carrier to the front subframe assembly.
    Figure 7. LH side
    Figure 8. RH side
  54. Remove the bolt that attaches the LH stabilizer bar mount to the body through the front subframe assembly. Repeat this step on the RH stabilizer bar mount.
    Figure 9. LH side
  55. Remove the LH rear bolt that attaches the front subframe assembly to the body. Repeat this step on the RH rear bolt.
    Figure 10. LH side
    Figure 11. RH side
  56. Lower the front subframe assembly completely, and then move the front subframe assembly from under the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not work on the front subframe assembly while it is under the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage the front end carrier while the front subframe assembly is lowered from the vehicle. The powertrain table must be tilted on the rear side angle down and the front side tilted up as the front subframe is clearing the front end carrier.

Installation

  1. Put the front subframe assembly with the powertrain table/subframe fixture under the vehicle for installation.
  2. Raise the front subframe assembly into position to be installed.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not work on the front subframe assembly while it is under the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage the front end carrier while the front subframe assembly is raised to the vehicle. The powertrain table must be tilted on the rear side angle down, and the front side tilted up as the front subframe is clearing the front end carrier.
  3. Install the RH rear bolt that attaches the front subframe assembly to the body (torque 115 Nm). Repeat this step on the LH rear bolt.
    Figure 12. RH side
    Figure 13. LH side
  4. Install the bolt that attaches the RH stabilizer bar mount to the body through the front subframe assembly (torque 80 Nm). Repeat this step on the LH stabilizer bar mount.
  5. Install new bolts (x4) that attach the bumper carrier to the front subframe assembly (torque 7.5 Nm).
    Figure 14. LH side
    Figure 15. RH side
  6. Lower the powertrain table, and then remove it from under the vehicle.
  7. Disconnect the shop air supply from the powertrain table.
  8. Put the coolant drain container under the LH front corner of the vehicle to catch any coolant during the next step.
  9. Install the fir tree clips (x3) that attach the battery coolant heater-to-coolant pump 2 between the steering rack and the front subframe.
  10. Remove the hose plugs, and then install the battery coolant heater-to-coolant pump 2 hose at the rear of the front subframe assembly and secure it with the hose clamp.
  11. Remove the hose plug, and then secure the hose clip and the fir tree clip that attach the coolant hose to the radiator inlet.
  12. Remove the coolant drain container from under the vehicle.
  13. Slide the lower i-shaft onto the steering rack, and then install the bolt that attaches the lower i-shaft to the steering rack (torque 30 Nm).
  14. Install a new nut that attaches the RH stabilizer bar to the stabilizer bar end link (torque 70 Nm). Repeat this step on the LH stabilizer bar.
    Figure 16. LH shown, RH similar
  15. Move the RH front fore link into the front subframe assembly, properly align the paint marks, and then hand-tighten the bolt that attaches the RH front lower fore link to the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt will be fully tightened during wheel alignment later in this procedure (torque specification for the bolt is 130 Nm).
  16. Move the RH front lower aft link into position on the front subframe assembly, and then hand-tighten the bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the bolt is installed with the bolt head facing the front of the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt will be fully tightened during wheel alignment later in this procedure (torque specification for the bolt is 130 Nm).
  17. Move the LH front lower fore link into the front subframe assembly, properly align the paint marks, and then hand-tighten the bolt that attaches the link to the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt will be fully tightened during wheel alignment later in this procedure (torque specification for the bolt is 130 Nm).
  18. Move the LH front lower aft link into position on the front subframe assembly, and then hand-tighten the bolt that attaches the link to the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the bolt is installed with the bolt head facing the front of the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt will be fully tightened during wheel alignment later in this procedure (torque specification for the bolt is 130 Nm).
  19. Install the bolt that attaches the LH front strut to the front lower aft link. Repeat this step on the RH front strut.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque the bolts at ride height when the vehicle is on the alignment rack later in this procedure (torque specification for the bolt is 140 Nm).
    Figure 17. LH side
    Figure 18. RH side
  20. Pull on the LH and RH front inner halfshaft cups to confirm that the circlip is locked into place. If the halfshaft detaches from the drive unit then reinstall the halfshaft and then test that it is fully seated.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If reinstalling the halfshaft to the drive unit:
    • Take care not to damage or displace the oil seals.
    • Make sure that the opening of the snap rings are facing towards the bottom of the drive unit.
    • Carefully push the halfshaft into the drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
    • There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
    • Pull on the inner halfshaft cup to confirm that the circlip is locked into place. If the halfshaft detaches from the drive unit then reinstall the halfshaft and then test that it is fully seated.
  21. Install the front subframe skid bar. See Skid Bar - Front Subframe (Remove and Replace) .
  22. Install the front skidplate. See Skidplate - Front (Remove and Replace) .
  23. Install the front bash plate stamping. See Bash Plate - Front - Stamping (Remove and Replace) .
  24. Install the ABS pump onto the rubber mounting grommet, and then install the nuts (x2) that attach the ABS pump to the front subframe (torque 9 Nm).
  25. Install the bolts (x2) that attach the LH stay bar to the front subframe assembly (torque 11 Nm). Repeat this step on the RH stay bar.
  26. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  27. Install the HV battery assembly. See HV Battery (RWD/AWD) (Remove and Install) .
  28. Install the front extrusion bash plate. See Bash Plate - Front - Extrusion (Remove and Replace) .
  29. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace) .
  30. Lower the vehicle partially.
  31. Install the LH tie rod end into the knuckle, and then install a new LH nyloc nut that attaches the tie rod end to the steering knuckle (torque 103 Nm). Repeat this step on the RH tie rod end.
    Figure 19. RH tie rod
    Figure 20. LH tie rod
  32. Install the LH and RH front wheels. See Wheel Assembly (Remove and Install) .
    Informational PurposesAn informational icon, calling your attention
    Note
    Before installing the LH and RH front wheel center caps, tighten the LH and RH front axle nuts (torque 245 Nm).
  33. Tighten the bolt that attaches the 3-way valve to the front subframe assembly (torque 5 Nm).
  34. Release the air suspension pump bracket and chiller assembly from the front end carrier.
  35. Install the bolts (x2) that attach the air suspension pump bracket to the front subframe assembly (torque 5.5 Nm).
  36. Install the bolts (x3) that attach the chiller assembly to the front subframe assembly (torque 5 Nm).
  37. Connect the electrical connectors (x2) for the steering rack logic.
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage the gray locks after the electrical connectors are fully seated.
  38. Install the clip that attaches the logic harness connector to the front subframe assembly.
  39. Connect the steering rack electrical connectors (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the red locking tab is engaged after hearing an audible click when connecting the steering rack connectors.
  40. Remove the plugs from both the coolant hose from the 4-way valve and the battery pump 2, immediately connect the hose to the pump, and then fasten the hose clamp that attaches the hose to the pump.
  41. Remove the absorbent material from under the battery pump 2.
  42. Slide the battery pump 2 onto the mounting bracket at the front subframe assembly.
  43. Reconnect 12V power. See Disconnect 12V Power .
  44. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  45. Install the underhood storage carpet. See Carpet - Underhood Storage (Remove and Install) .
  46. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  47. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  48. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  49. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  50. Connect a laptop with Toolbox to the vehicle.
  51. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Coolant Air Purge, click Run, and allow the routine to complete.
  52. Top off the coolant reservoir and reinstall the coolant bottle cap, if necessary.
  53. Install the mid aero shield. See Panel - Aero Shield - Mid (Remove and Replace) .
  54. Close the hood.
  55. Disconnect the laptop from the vehicle and reinstall the storage cubby.
  56. Position the front passenger seat back to its original position.
  57. Remove the steering wheel holder from the vehicle.
  58. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the front fore links, front lower fore links, and the front lower aft links are tightened to specifications during this procedure.
  59. Install the mid aero shield panel.
  60. Remove the brake pedal depressor, the steering wheel level, the steering wheel holder from the vehicle, and then shift into Park.
  61. Remove the wheel chocks, and then remove the vehicle from the 4-post lift.
  62. Perform a vehicle test drive.