23/08/2022 10:16:40

Drive Unit - Front (1st Generation) (Remove and Install)

Correction Code 39012101

Special tools required for this procedure:

Supplier Part Number Description
Bosch FMG-750 Transmission Jack 750 Kg Europe only
Tesla 1053350-00-A Transmission Jack Cradle Adapter Plate Europe only
Tesla 1063141-00-A 1/2 Ton Economy Transmission Jack North America, APAC only
Tesla 1048391-00-B Drive Unit Dual Motor Cradle - Delrin white
Tesla 1083189-**-A Tool, ATF oil refiller
Tesla 1498673-00-A KIT, CABLE AXLE REMOVER, MS/MX/M3

This procedure is for vehicles built through April 24, 2019. For vehicles built after April 24, 2019, see Drive Unit - Front (2nd Generation) (Remove and Install).

Removal

  1. Position the vehicle on a two post lift, but do not raise it at this time.
  2. Engage the electric park brake.
  3. Remove the center cap from the LH front wheel.
  4. Loosen the LH front axle nut, but do not remove it.
  5. Remove the center cap from the RH front wheel.
  6. Loosen the RH front axle nut, but do not remove it.
  7. Recover the refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  8. Remove the front subframe. See Subframe Assembly - Front (1st Generation) (Dual Motor) (Remove and Install) .
  9. Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  10. Release the fir tree clips (x2) that attach the 12V positive harness to the front crossmember.
  11. Move the 12V positive harness to the RH side of the vehicle to keep it out of the working area.
    Figure 1. Harness highlighted in yellow
  12. Make sure that the coolant reservoir cap is properly secured.
  13. Remove the bolts (x4) that attach the coolant reservoir to the front crossmember.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the reservoir at this time.
  14. Carefully lift up the coolant reservoir and disconnect the electrical harness from the coolant level sensor connector.
  15. Move the coolant reservoir forward into the underhood area.
    Informational PurposesAn informational icon, calling your attention
    Note
    The reservoir hose is routed behind the front drive unit hose. Make sure that hoses are correctly routed during reinstallation.
  16. Release the clips (x4) that attach the hoses to the front crossmember.
  17. Release the clip that attaches the coolant reservoir hose to the A/C line.
  18. Clamp the coolant hose that leads to the differential housing on the LH side of the 3-way fitting.
  19. Remove the hose from the front drive unit and plug the fitting.
  20. Move the coolant reservoir to the LH side of the vehicle and secure it out of the working area.
    Informational PurposesAn informational icon, calling your attention
    Note
    The coolant hoses (x2) are still attached to the coolant reservoir.
  21. Clamp the coolant hose on the LH side of the front drive unit.
  22. Remove the hose and plug the fitting.
    Tip: Use flexible hose clamp pliers to release the locking ring.
  23. Move the clamped front drive unit coolant hose to the RH side of the vehicle so that it is out of the working area.
  24. Release the clip that attaches the LH A/C line to the compressor HV harness.
  25. Remove the nuts (x2) that attach the A/C lines to the compressor.
  26. Plug both holes on the compressor and cap both lines.
  27. Disconnect the electrical harness from the compressor LV connector.
  28. Remove the bolt that attaches the ground strap to the compressor bracket.
  29. Release the edge clip that attaches the electrical harnesses to the compressor bracket.
  30. Release the fir tree clip that attaches the electrical harness to the top of the front drive unit.
  31. Wrap the electrical harness around the RH hood strut so that they are out of the working area.
  32. With the help of an assistant, remove the bolts (x3) that attach the compressor bracket to the front drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not spill any oil from the compressor. If oil spills from the compressor, the system might experience a failure due to inadequate lubrication after reinstallation.
  33. Move the compressor and bracket to the RH side of the vehicle and secure them outside of the working area.
  34. Remove the bolt that attaches the ground strap to the front drive unit.
  35. Disconnect the electrical harness from the front drive unit motor logic connector.
  36. Raise the vehicle to access the wheel wells.
  37. Remove the screws (x4) that attach the HV cables to the front drive unit.
  38. Fully raise the vehicle.
  39. Remove the front drive unit lower RH acoustic cover.
  40. Drain the gearbox fluid. See Gearbox Fluid - Front Drive Unit (1st Generation) (Drain and Refill) .
  41. Clamp the coolant hoses (x2) that lead to coolant pump 4 at the locations indicated.
  42. Release the locking rings and disconnect the coolant hoses from coolant pump 4.
  43. Remove the LH halfshaft. See Halfshaft - Front Drive Unit - LH (1st Generation) (Remove and Replace) .
  44. Remove the jackshaft. See Jackshaft Assembly - Front (Remove and Replace) .
  45. Europe only: Install the adapter plate onto the transmission jack.
  46. Install the front drive unit cradle onto the transmission jack.
  47. Position the transmission jack fixture underneath the front drive unit.
  48. Raise the transmission jack to support the weight of the front drive unit.
  49. With the help of an assistant, make sure that the ridge on the base of the front drive unit fits into the channel on the transmission jack.
  50. Use the front drive unit cradle strap to secure the front drive unit.
  51. Loosen, but do not remove, the front adjustment bolts (x2) of the LH motor mount.
  52. Remove and discard the bolts (x2) that attach the RH motor mount to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    The RH motor mount remains with the front drive unit.
  53. Remove and discard the bolts (x2) that attach the LH motor mount to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    The LH motor mount remains with the front drive unit.
  54. Lower the front drive unit to a working height.

Installation

  1. Remove the old bolts, and then hand-tighten new LH motor mount adjustment bolts (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    This step is performed with the drive unit out of the vehicle.
  2. Raise the front drive unit up into the vehicle and hand-tighten new bolts that attach the LH (x2) and RH (x2) motor mounts to the body.
  3. Install the shim kit onto the RH motor mount.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the shims cannot be positioned, loosen the drive unit mount bolts and reposition the drive unit as necessary.
  4. Torque the bolts (x2) that attach the LH motor mount to the body (torque 65 Nm).
  5. Torque the LH motor mount adjustment bolts (x2) (torque 50 Nm).
  6. Torque the bolts (x2) that attach the RH motor mount to the body (torque 120 Nm).
    Figure 2. Parts hidden for clarity
  7. Check the fitment of the alignment shims.
    Informational PurposesAn informational icon, calling your attention
    Note
    If alignment shims do not slide in and out of place easily, loosen the LH motor mount adjustment bolts and repeat torque steps.
  8. Remove the shims from the vehicle.
  9. Release the cradle strap from the front drive unit.
  10. Lower the transmission jack, and move it out from under the vehicle.
  11. Remove the front drive unit cradle from the transmission jack.
  12. Europe only: Remove the adapter plate from the transmission jack.
  13. Install the jackshaft. See Jackshaft Assembly - Front (Remove and Replace) .
  14. Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    When the drive unit was replaced by a new or remanufactured unit, before installing the LH halfshaft make sure to complete the checks on the LH output seal as described in the Installation section of .
    Install the LH halfshaft. See Halfshaft - Front Drive Unit - LH (1st Generation) (Remove and Replace) .
  15. Align the LH halfshaft so that the opening in the snap ring is down, facing towards the bottom of the front drive unit.
  16. Insert the LH halfshaft into the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not damage or displace the oil seal.
  17. Carefully push the LH halfshaft into the front drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
  18. Pull on the LH inner halfshaft cup to confirm that the LH halfshaft circlip is locked into place.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the halfshaft detaches from the front drive unit, repeat from step 15 and then test that the halfshaft is fully seated.
  19. Repeat step 15 through 18 for the RH halfshaft.
  20. Connect the coolant hoses to coolant pump 4, and then fasten the locking rings.
  21. Remove the clamps from the coolant hoses (x2) at coolant pump 4.
  22. Install the front drive unit lower RH acoustic cover.
  23. Lower the vehicle to a working height.
  24. Carefully inspect the connector seals of the HV cables. If any are damaged, replace them.
  25. Apply P-80 emulsion to the connector seals of the HV cables.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply P-80 emulsion to the HV terminals.
  26. Insert the HV cables into the front drive unit, and then install the screws (x4) that attach the HV cables to the front drive unit (torque 7 Nm).
  27. Connect the electrical harness to the front drive unit motor logic connector.
  28. Install the ground strap to the front drive unit, and then install the bolt that attaches the ground strap to the front drive unit (torque 6 Nm).
  29. Release the compressor and bracket, and move them back to where the compressor installs.
  30. With the help of an assistant, install the bolts (x3) that attach the compressor bracket to the front drive unit (torque 10 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not spill any oil from the compressor. If oil spills from the compressor, the system might experience a failure due to inadequate lubrication after reinstallation.
  31. Release the electrical harness from around the RH hood strut.
  32. Fasten the fir tree clip that attaches the electrical harness to the top of the front drive unit.
  33. Fasten the edge clip that attaches the electrical harnesses to the compressor bracket.
  34. Install the ground strap to the compressor bracket, and then install the bolt that attaches the ground strap to the compressor bracket (torque 7 Nm).
  35. Connect the electrical harness to the compressor LV connector.
  36. Remove the plugs from the A/C compressor, and remove the caps from the A/C lines.
  37. Insert the A/C lines into the compressor, and then install the nuts (x2) that attach the A/C lines to the compressor (torque 10 Nm).
  38. Fasten the clip that attaches the LH A/C line to the compressor HV harness.
  39. Return the front drive unit coolant hose from the RH side of the vehicle to the front drive unit.
  40. Unplug the fitting on the front drive unit, install the coolant hose, and then use flexible hose clamp pliers to fasten the locking ring.
  41. Remove the clamp from the coolant hose.
  42. Release the coolant reservoir, and return it from the LH side of the vehicle.
  43. Unplug the fitting on the front drive unit, install the coolant hose, and then use flexible hose clamp pliers to fasten the locking ring.
  44. Remove the clamp from the coolant hose.
  45. Fasten the clip that attaches the coolant reservoir hose to the A/C line.
  46. Fasten the clips (x4) that attach the hoses to the front crossmember.
  47. Return the coolant reservoir rearward from the underhood area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the reservoir hose is routed behind the front drive unit hose.
  48. Connect the electrical harness to the coolant level sensor connector.
  49. Install the coolant reservoir onto the front crossmember, and then install the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 Nm).
  50. Return the 12V positive harness from the RH side of the vehicle.
    Figure 3. Harness highlighted in yellow
  51. Fasten the fir tree clips (x2) that attach the 12V positive harness to the front crossmember.
  52. Install the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  53. Install the front subframe. See Subframe Assembly - Front (1st Generation) (Dual Motor) (Remove and Install) .
  54. Recharge the A/C system. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  55. Refill the drive unit with gearbox fluid. See Gearbox Fluid - Front Drive Unit (1st Generation) (Drain and Refill).
  56. Install the front wheels. See Wheels - Axle Set (Remove and Install).
  57. Engage the electric park brake.
  58. Fully lower the vehicle and remove it from the 2-post lift.