2025-03-26

Intermediate Shaft - Steering Column - Lower (Dual Motor) (1st Generation) (Remove and Replace)

Correction Code 32011602

Procedure

2025-03-26: Updated steps on accessing the intermediate shaft bolts.

Note

This procedure is for vehicles built before April 10, 2016. For vehicles built after April 10, 2016: See Intermediate Shaft - Steering Column - Lower (Dual Motor) (2nd Generation) (Remove and Replace).

Open LH front door
Lower LH front window
Raise and support vehicle

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
Open hood

Note
Via Controls > Front Trunk
Remove LH apron

Note
9x clips
Remove RH apron

Note
9x clips
Remove rear apron

Note
8x clips
Remove bolt securing lower I-shaft to upper I-shaft

Note
1x patch bolt, 16mm, 50 Nm, 1x nut,15mm, 50 Nm, Discard after removal, move steering wheel as needed
Raise vehicle fully and lower lift onto locks

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
Remove clips securing front aero shield to vehicle

Note
14x push clips
Remove front aero shield

Note
6x bolts, 10mm, 3 Nm, 2x bolts, T40, 4 Nm
Remove front bash plate extrusion

Note
2x bolts, T30, 16 Nm
Remove bash plate lower stamping

Note
2x bolts, 10mm, 9 Nm
Remove front four HV battery bolts

Note
4x patch bolts, 13mm, 30 Nm, Discard after removal
Remove skid plate from between HV Battery and front subframe

Note
Slowly pry bash plate out to ease removal
Remove bolt between lower I-shaft to steering rack

Note
1x bolt, 16 mm, 50 Nm, Discard bolt after removal, Access to bolt can also be achieved from LH front wheel well
Lower vehicle
Install steering wheel holder

Note
Center steering wheel
Raise vehicle fully and lower lift onto locks

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
Separate lower I-shaft from steering gear

Note
Lower I-shaft is keyed to the steering gear, Lightly tap on the shaft to remove
Lower vehicle
Separate upper and lower I-shafts and remove lower I-shaft from vehicle

Note
Push the upper I-shaft inwards
Apply lubricant onto seals of lower I-shaft

Note
Use a brush to apply the Krytox 224 performance lubricant between the crevices of each seal on the I-shaft
Install lower I-shaft onto upper I-shaft

Note
1x nut, 15mm, 1x bolt, 16mm, 50 Nm, Verify proper mating, Install new fasteners, torque at later step, In cold/humid or corrosive/ocean regions use corrugated boot
Remove steering wheel holder from vehicle
Raise vehicle fully and lower lift onto locks

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
Install lower I-shaft to steering gear

Note
1x patch bolt, 16 mm, 50 Nm, the lower I-shaft is keyed to the steering gear, Install new fastener, Manipulate and move the steering gear or steering wheel as needed, Access to bolt can also be achieved from LH front wheel well, Mark bolt after it is torqued
Install skid plate between HV Battery and front subframe
Install four front HV battery bolts

Note
4x bolts, 13mm, 30 Nm, Install new patch bolts
Install bash plate stamping and skid plate to front subframe

Note
2x bolts, 10mm, 9 Nm
Install front bash plate extrusion

Note
2x bolts, T30, 16 Nm
Install front aero shield onto vehicle

Note
6x bolts, 10mm, 3 Nm, 2x bolts, T40, 4 Nm
Install clips securing front aero shield to vehicle

Note
14x push clips
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque bolt securing lower I-shaft to upper I-shaft

Note
1x nut, 15mm, 1x bolt, 16mm, 50 Nm, Mark bolt after it is torqued, move steering wheel as needed
Install RH underhood apron

Note
9x clips
Install LH underhood apron

Note
9 x clips
Install rear underhood apron

Note
8x clips
Close hood

Note
Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
Connect laptop to vehicle with a tethered Ethernet connection via Toolbox 3

Note
1x connector, 2x clips, Newer models will access connector below MCU with cubby removed, Older models will access port at LH side of IP with end cap removed. Open Toolbox 3 website and establish connection to vehicle: https://toolbox.teslamotors.com, Select connection status icon at top right corner and select Connect Locally (icon will turn green when vehicle is connected), Local connection will enable service mode plus on display
On the MCU 'Service Mode' menu open 'Can Viewer'
Select the signals StW_AnglHP and EPAS_torsionBarTorque

Note
CH>STW_ANGLHP_STAT>StW_AnglHPCH>EPAS_sysStatus>EPAS_torsionBarTorque
Perform Lock to Lock test

Note
Turn the steering to the left lock stop and hold TorsionBarTorque at 10 Nm while reading the angle. Record this value. Perform the same for the right side. Record this value. Compare the 2 angle values. The readings must not exceed more then 6 degrees apart between left and right (for example, 460 L, 530 R are 70 degrees apart)
Disconnect Toolbox from vehicle and install cubby under MCU

Note
1x connector, 2x clips, Ensure diagnostic cables are tucked into appropriate position then engage cubby
Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE''
Raise LH front window
Close LH front door

Model S Service Manual

Intermediate Shaft - Steering Column - Lower (Dual Motor) (1st Generation) (Remove and Replace)

Procedure

Figure 1

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Figure 3