25/03/2024 17:25:14

Mount - Front Drive Unit - RH (2nd Generation) (Remove and Replace)

Correction code 39012422 6.9 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 to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See to make sure wearing proper PPE when performing the below procedure.

2023-09-19: Updated torque value for RH side mount bolts.

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.

Removal

This procedure is for vehicles built after April 24, 2019. For vehicles built through April 24, 2019, see Mount - Front Drive Unit - RH (1st Generation) (Remove and Replace).

Verify there is no abnormal tire wear per Courtesy Inspection

Note
SC-14-00-001 Standard Courtesy Inspection Checklist, While performing courtesy inspection, Note any abnormal tire wear that could indicate the need for an alignment
Set up A/C machine and perform hose flush

Note
Touch time only
Open all four doors
Lower all four windows
Raise and support vehicle

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 3

Note
1x connector, 2x clips, Remove cubby under MCU and connect laptop to vehicle, 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
Unlock vehicle Gateway

Note
After vehicle has been put into "Service Mode", hold down the brake pedal, while holding down break pedal simultaneously hold the turn signal stalk fully up for at least 10 seconds, "GTW UNLOCKING" should pop up on the instrument cluster right below the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 899" will be displayed on the instrument cluster underneath the VIN, the gateway will remain unlocked for 15 minutes, follow steps on Toolbox article #5582900 for any additional information
Select ‘Actions’ tab and search for ‘PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain’
Select Action 'Start' , Fluid Fill Target 'Refrigerant' and press 'Run'

Note
Check the Routine's Notes before pressing Run, Verify successfully ''Passed'
Wait to see that the routine 'Passed' successfully

Note
Now the system is ready for Fill / Drain
Install steering wheel lock to ensure proper placement of the steering wheel
Move RH front seat fully forward
Open hood

Note
Via Controls > Front Trunk
Remove rear underhood apron

Note
8x clips
Remove RH underhood apron

Note
9x clips
Remove LH underhood apron

Note
9x clips
Remove front underhood apron

Note
7x clips
Release drainage hoses from HEPA filter inlet duct

Note
2x hoses
Remove clips securing HEPA filter inlet duct to cowl panel

Note
3x push clips
Remove HEPA filter inlet duct

Note
2x clips on HEPA filter
Remove HEPA filter outlet duct from vehicle

Note
Lift up, pull towards front of vehicle, then rotate clockwise
Remove dust caps from high-side and low-side service ports

Note
2x caps
Connect hoses to vehicle and perform A/C recovery

Note
Touch time only, Ensure quick connects are fully engaged, Turn the connector dials clockwise to fully connect to A/C service ports
Disconnect light and release switch connectors and remove underhood storage carpet

Note
2x connectors, Release edge of carpet from underneath underhood storage unit seal
Remove bolts and clips securing underhood storage unit

Note
2x bolts, 10mm, 7 Nm, 2x push clips
Push wiring harness grommet through underhood storage unit and remove underhood storage unit

Note
1x grommet, Lift the underhood storage unit appropriately to access the grommet
Power off vehicle via UI

Note
Via Controls > Safety > Power Off
Disconnect 12V negative terminal and First Responder Loop

Note
1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
Remove 2nd row seat bottom cushion

Note
2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
Remove NVH padding from underneath 2nd row seat cushion

Note
If equipped
Remove bolts securing seat bottom frame

Note
8x bolts, 11mm, 26 Nm
Lift up and support seat bottom frame

Note
8x clips
Remove tamper evident label from charger cover panel
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves
Release HV charger access panel cover

Note
11x bolts, T20, 2 Nm, Discard after removal
Release tabs and open both access doors

Note
4x tabs, Make sure to wear proper PPE
Verify no high voltage

Note
Measure B+ to B-, B+ to ground, and B- to ground, Make sure to wear proper PPE, Verify you are using a proper ground and not a coated surface, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work escalate a toolbox session for assistance
Secure HV charger access panel cover

Note
11x bolts, T20, 2 Nm, Install new patch bolts
Remove HV insulating gloves
Install new warranty label onto charger cover panel

Note
Wipe charger with IPA prior to installation, Allow 1 minute for IPA to dry
Lower seat frame into position and secure harness clips to frame

Note
8x clips
Install and torque bolts securing seat frame to vehicle

Note
8x bolts, 11mm, 26 Nm
Place NVH padding onto seat frame
Install seat bottom cushion

Note
2x clips, 7x connectors if equipped, Replace clips if necessary
Remove A/C lines from vehicle

Note
Press clear lines once lines have been removed
Release chiller assembly from front subframe

Note
3x bolts, 10mm, 5 Nm
Slide battery pump 2 off of the bracket secured to subframe

Note
Slide pump to the right of vehicle for removal
Disconnect steering rack connectors

Note
2x connectors, 2 stage locking connectors, Disengage the red locking tab before disconnecting
Disconnect the logic connectors for the steering rack

Note
2x electrical connectors, 2-way connectors, slide the grey lock out, then depress the lock to disconnect
Release logic connector harness from subframe

Note
1x fir tree clip
Remove the fasteners securing air suspension pump bracket to subframe

Note
2x bolts, 10mm, 5.5 Nm
Secure air suspension pump bracket and chiller assembly to front end carrier

Note
Use bungee cord or something similar to hold assemblies in general position
Remove accessible bolt on RH 3-way valve

Note
1x bolt, T30, 5 Nm, Remaining bolt will be removed at later step
Remove 12V positive terminal cover

Note
2x tabs
Disconnect 12V positive terminal

Note
1x nut, 10mm, 6 Nm
Remove fasteners securing 12V battery bracket to shock tower cross member and the battery beam

Note
2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
Remove 12V battery bracket assembly

Note
2x clips
Remove fastener securing coolant hose to battery beam

Note
1x bolt, T30, 5 Nm
Remove fasteners securing the battery beam to the LH and RH body beams

Note
2x bolts, T30, 3.5 Nm, 1x edge clip
Remove the battery beam
Disconnect coolant reservoir level sensor

Note
1x connector
Disconnect AC compressor logic connector

Note
1x connector
Release ground connection at the A/C compressor mount bracket

Note
1x bolt, T25, 7 Nm
Remove AC lines from compressor

Note
2x nuts, 10mm, 10 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
Release ground strap from front drive unit

Note
1x bolt, E10, 6 Nm
Disconnect logic connector from front drive unit

Note
1x connector with lock tab
Remove lug nut covers from LH front wheel

Note
5x covers
Remove lug nut covers from RH front wheel

Note
5x covers
Remove RH front wheel center cap

Note
1x cap
Remove LH front wheel center cap

Note
1x cap
Loosen LH front axle nut

Note
1x nut, 32mm, 245 Nm
Loosen RH front axle nut

Note
1x nut, 32mm, 245 Nm
Loosen RH front wheel

Note
5x nuts, 21mm, 175 Nm
Loosen LH front wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle partially and lower onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
Remove LH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove LH tie rod nut and move tie rod end away

Note
1x Nyloc nut, 21mm, 103 Nm, Discard after removal
Remove RH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH tie rod nut and move tie rod end away

Note
1x Nyloc nut, 21mm, 103 Nm, Discard after removal
Remove nuts and bolts securing RH front wheel arch liner

Note
2x nuts, 10mm, 4 Nm, 3x bolts, 10mm, 4 Nm
Remove clips securing RH front wheel arch liner

Note
7x push clips
Release clips and remove RH front wheel arch liner from vehicle

Note
3x clips
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 LH shear plate to wheel fairing

Note
2x push clips
Remove LH shear plate

Note
2x clips, 1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
Remove clips securing RH shear plate to wheel fairing

Note
2x push clips
Remove RH shear plate

Note
2x clips, 1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
Remove bolts securing mid aero shield to vehicle

Note
7x bolts, 10mm, 4 Nm
Remove clips securing mid aero shield to vehicle

Note
7x push clips
Remove mid aero shield from vehicle
Remove front bash plate extrusion

Note
2x bolts, T30, 16 Nm
Remove LH ski side covers

Note
14x push clips, 3x covers
Remove RH ski side covers

Note
14x push clips, 3x covers
Remove four center bolts securing HV battery

Note
4x patch bolts, E12, 38 Nm, Discard after removal
Position battery table beneath vehicle
Lower vehicle to table

Note
Recommend assistance, Align table to vehicle and raise casters to level table if necessary
Remove remaining eight center bolts securing HV battery

Note
8x patch bolts, E12, 38 Nm, Discard after removal
Remove front four HV battery bolts

Note
4x patch bolts, 13mm, 30 Nm, Discard after removal
Remove 21mm bolts securing front of HV battery

Note
2x bolts, 21mm, 115 Nm, Discard after removal
Remove LH rocker bolts

Note
8x patch bolts, 13mm, 55 Nm, Discard after removal
Remove RH rocker bolts

Note
8x patch bolts, 13mm, 55 Nm, Discard after removal
Raise vehicle off HV battery
Move battery away from vehicle
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves
Verify no high voltage at HV rapid mate

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Install HV and LV Rapid Mate covers

Note
2x covers, If covers not available then use masking tape to protect Rapid Mate from debris
Remove HV insulating gloves
Remove clips securing front aero shield to vehicle

Note
10x push clips
Remove bolts securing front aero shield to vehicle and remove

Note
12x bolts, 10mm, 4 Nm
Remove skid bar from front subframe

Note
4x bolts, 10mm, 10 Nm
Remove the bolts securing the bash plate stamping and skid plate to the front subframe skid plate

Note
2x bolts, 10mm, 9 Nm
Remove skid plate from front subframe

Note
2x bolts, 10mm, 9 Nm
Remove nut and bolt securing RH front air spring module to front lower aft link

Note
1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Use pry bar to release tension from air spring module to control arm
Remove nut and bolt securing LH front air spring module to front lower aft link

Note
1x bolt, 21mm, 1x nut, 21mm, 140 Nm
Remove the fasteners securing the LH front lower aft link to the subframe and move the aft link aside

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
Remove the fasteners securing the LH front lower fore link to the subframe and move the fore link aside

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
Remove the fasteners securing the RH front lower aft link to the subframe and move the aft link aside

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
Remove the fasteners securing the RH front lower fore link to the subframe and move the fore link aside

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
Remove LH stabar nut from the stabar and move LH stabar end link away from the bar

Note
1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal
Remove RH stabar nut from the stabar and move RH stabar end link away from the bar

Note
1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal
Remove the bolt securing the lower i-shaft to the steering gear and slide the i-shaft up away from the steering gear

Note
1x bolt, 13mm, 30 Nm
Remove forward bolt securing RH 3-way valve to subframe bracket

Note
1x bolts, T30, 5 Nm
Remove the LH stay bar

Note
2x bolts, 10mm, 11 Nm
Remove the RH stay bar

Note
2x bolts, 10mm, 11 Nm
Remove nuts holding ABS pump to subframe and release from rubber grommet

Note
2x nuts, 10mm, 9 Nm, 1 rubber grommet
Position coolant drain container under the front of the vehicle to catch vehicle coolant
Disconnect FDU inlet hose and plug both openings

Note
1x hose clip, 1x fir tree clip
Disconnect the hose from the battery coolant heater to coolant pump 2 at the rear of the subframe and plug the ends

Note
1x hose clamp, 3x fir tree clips, Make sure to remove hose from between steering rack and subframe
Move coolant drain container below right side of FDU
Disconnect coolant hose from radiator inlet and plug the open connections

Note
1x hose clip, 1x fir tree clip
Remove coolant drain container from underneath vehicle
Remove the fasteners securing the FJB to FDU HV harness to the FJB

Note
4x bolts, T30, 7 Nm, Discard bolts after removal
Disconnect AC HV cable from front junction box

Note
1x connector, 2 stage locking connectors
Position the powertrain table with the Model S/Model X subframe adapter installed under the front of the vehicle
Connect shop air supply to the powertrain table
Raise the powertrain table and subframe fixture into position

Note
Ensure the pins are installed into the correct positions on the fixture, Ensure the pins engage the subframe so it is properly supported
Remove the bolts that secure the front subframe to the bumper carrier

Note
4x patch bolts, 10mm, 7.5 Nm, Discard after removal
Remove the fastener connecting the LH stabar mount to the body through the subframe

Note
1x bolt, 16mm, 80 Nm
Remove the fastener connecting the RH stabar mount to the body through the subframe

Note
1x bolt, 16mm, 80 Nm
Remove the LH rear bolt securing the front subframe to the body

Note
1x bolt, 18mm, 115 Nm
Remove the RH rear bolt securing the front subframe to the body

Note
1x bolt, 18mm, 115 Nm
Lower the front subframe, and move the assembly from under the vehicle

Note
The powertrain table will need to be tilted with rear side angled down and front side tilted up as the subframe is clearing front end carrier, Take caution not to damage front end carrier
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Remove LH front axle nut and washer

Note
1x nut, 32mm, 245 Nm, Discard after removal
Install hub puller onto the LH front brake rotor

Note
5x lug nuts, 21mm, Hand tight
Use hub puller to free LH halfshaft from hub splines

Note
Counter hold hub adapter
Remove hub puller from LH hub assembly

Note
5x lug nuts, Hand tight
Remove LH halfshaft from LH hub assembly

Note
Adjust hub puller if further clearance is needed to free shaft from knuckle
Install the axle removal tool around the inner joint of the LH front halfshaft

Note
Use a wire tie to hold the axle removal tool in place
Remove LH front halfshaft from the drive unit and remove from the vehicle
Remove axle nut and washer securing RH drive axle to hub assembly

Note
1x nut, 32mm, 245 Nm
Install the hub puller onto the RH front brake rotor

Note
5x lug nuts, 21mm, Hand tight
Use hub puller to free RH halfshaft from hub splines

Note
Counter hold hub adapter
Remove hub puller from RH hub assembly
Remove RH halfshaft from RH hub assembly

Note
Adjust hub puller if further clearance is needed to free shaft from knuckle
Install the axle removal tool around the inner joint of the RH front halfshaft

Note
Use a wire tie to hold the axle removal tool in place
Remove RH front halfshaft from the drive unit and remove from the vehicle
Position transmission jack fixture under drive unit

Note
Secure FDU strap
Remove bolts from LH FDU mount to body

Note
2x bolts, E14, 65 Nm
Remove bolts securing RH FDU mount to body

Note
2x bolts, EP20, 120 Nm
Lower front drive unit with jack out of vehicle
Remove the bolts (x4) that attach the RH side mount onto the front drive unit, and then remove t he mount from the drive unit.

Installation

Install the RH side mount to the front drive unit, and then install and hand-tighten the bolts (x4) that attach the mount to drive unit.
Fully tighten the bolts (x4) that attach the RH side mount onto the front drive unit.
60 Nm (44.2 lbs-ft) +50 degrees
Raise the FDU into the vehicle
Loosely install bolts securing LH FDU mount to body

Note
2x bolts, E14, 65 Nm
Raise the FDU until the front fastener securing RH FDU mount to the body can be installed

Note
Visually inspect holes are aligned
Loosely install the front fastener securing the RH FDU mount to the body

Note
1x bolt, EP20, 120 Nm, Torque at later step
Install bolt securing rear of RH FDU mount

Note
1x bolt, EP20, 120 Nm
Torque bolt securing front of RH FDU mount to body

Note
1x bolt, EP20, 120 Nm
Fully secure bolts securing LH FDU mount to body

Note
2x bolts, E14, 65 Nm
Lower the FDU stand and underhoist stand away from the FDU
Install LH front halfshaft into the FDU

Note
Position C-clip opening at the bottom of axle to ease installation, Ensure the axle is fully seated into the drive unit, Straighten axle and apply pressure to opposite end until an audible click is heard when the C-Clip is fully engaged, If an audible click is not heard adjust shaft position and reinstall. For a visual indicator, inspect axle seal clamp is inline with base of FDU LH side mount bolt.
Apply Molykote M-77 to outboard side of LH front halfshaft

Note
Clean if necessary, Apply no more than 1 gram to axle only
Install LH front halfshaft into hub and bearing assembly and secure nut and washer hand tight

Note
1x nut, 1x washer, 32mm, 245 Nm, Torque at later step. Use the nut without the washer to pull the shaft through hub, Then remove nut and install the washer and nut. Do not use power tools, The risk of stripping the threads is very high.
Install RH front halfshaft into the FDU

Note
Position C-clip opening at the bottom of axle to ease installation, Ensure the axle is fully seated into the drive unit, Straighten axle and apply pressure to opposite end until an audible click is heard when the C-Clip is fully engaged, If an audible click is not heard adjust shaft position and reinstall.
Apply Molykote M-77 to outboard side of RH halfshaft

Note
Clean if necessary, Apply no more than 1 gram to axle only
Install RH halfshaft into hub and bearing assembly and secure nut and washer hand tight

Note
1x nut, 1x washer, 32mm, 245 Nm, Torque at later step. Use the nut without the washer to pull the shaft through hub, Then remove nut and install the washer and nut. Do not use power tools, The risk of stripping the threads is very high.
Position the subframe assembly under the vehicle for installation
Raise the subframe into position to be installed

Note
The powertrain table will need to be tilted with rear side angled down and front side tilted up as the subframe is clearing front end carrier, Take caution not to damage front end carrier
Install the RH rear bolt securing the front subframe to the body

Note
1x bolt, 18mm, 115 Nm
Install the LH rear bolt securing the front subframe to the body

Note
1x bolt, 18mm, 115 Nm
Install the fastener connecting the RH stabar mount to the body through the subframe

Note
1x bolt, 16mm, 80 Nm
Install the fastener connecting the LH stabar mount to the body through the subframe

Note
1x bolt, 16mm, 80 Nm
Install the bolts that secure the front subframe to the bumper carrier

Note
4x patch bolts, 10mm, 7.5 Nm, Install new bolts
Lower the powertrain table and remove it from under the vehicle
Disconnect shop air supply from the powertrain table
Connect AC HV cable to front junction box

Note
1x connector, Engage red locking tab
Install the fasteners securing the FJB to FDU HV harness to the FJB

Note
4x bolts, T30, 7 Nm, Install new patch bolts
Position coolant drain container under the LH front corner of the vehicle to catch vehicle coolant
Remove the plugs and connect FDU inlet hose

Note
1x hose clip, 1x fir tree clip
Remove the plugs and connect the hose from the battery coolant heater to coolant pump 2 at the rear of the subframe

Note
1x hose clamp, 3x fir tree clips, Make sure to route hose in between steering rack and subframe
Remove plugs and install FDU outlet hose

Note
1x hose clamp, 1x fir tree clip
Remove coolant drain container from underneath vehicle
Slide the lower i-shaft onto the steering gear and install the fastener

Note
1x bolt, 13mm, 30 Nm
Install nut securing RH stabar end link to stabar

Note
1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket
Install nut securing LH stabar end link to stabar

Note
1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket
Move the RH front fore link into the subframe and install the fastener

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Properly align the paint marks
Move the RH front lower aft link into position and install the fastener

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Ensure the bolt is installed with the bolt head facing the front of the vehicle
Move the LH front fore link into the subframe and install the fastener

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Properly align the paint marks
Move the LH front lower aft link into position and install the fastener

Note
1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Ensure the bolt is installed with the bolt head facing the front of the vehicle
Install nut and bolt securing LH front air spring module to front lower aft link

Note
1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Torque at later step
Install nut and bolt securing RH front air spring module to front lower aft link

Note
1x bolt, 21mm, 1x nut, 21mm, 140 Nm
Install skid bar to front subframe

Note
4x bolts, 10mm, 10 Nm
Install skid plate to front subframe

Note
2x bolts, 10mm, 9 Nm
Install bash plate lower stamping

Note
2x bolts, 10mm, 9 Nm
Install ABS pump to subframe

Note
2x nuts, 10mm, 9 Nm
Install LH stay bar

Note
2x bolts, 10mm, 11 Nm
Install RH stay bar

Note
2x bolts, 10mm, 11 Nm
Remove HV and LV Rapid Mate covers

Note
2x covers
Position HV battery underneath vehicle
Lower vehicle onto HV battery pack

Note
Before lowering fully use assistance to align the pack using the alignment rods and guide via the borescope camera or a flexible inspection mirror checking HV and LV rapid mates
Install front bolts for HV battery with power tool

Note
4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
Install 21mm bolts at front of HV battery with power tool

Note
2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step
Install outer center bolts with power tool

Note
8x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
Install LH rocker bolts with power tool

Note
8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
Install RH rocker bolts with power tool

Note
8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
Torque rocker HV battery bolts on both sides

Note
16x patch bolts, 13mm, 55 Nm
Torque remaining HV battery bolts

Note
8x patch bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x patch bolts, 13mm, 30 Nm
Raise vehicle and remove battery table

Note
Recommend assistance
Install inner center HV battery bolts with power tool

Note
4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts
Torque the inner center HV battery bolts

Note
4x patch bolts, E12, 38 Nm
Install LH ski side covers

Note
14x clips, 3x covers
Install RH ski side covers

Note
14x clips, 3x covers
Install front lower bash plate extrusion

Note
2x patch bolts, T30, 16 Nm
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Install nut securing LH front tie rod end to LH front knuckle

Note
1x nyloc nut, 21mm, 103 Nm, Install new nut
Install nut securing RH front tie rod end to RH front knuckle

Note
1x nyloc nut, 21mm, 103 Nm, Install new nut
Install LH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Position RH front wheelhouse liner onto vehicle

Note
3x clips, Route HEPA drain hose properly and secure clips
Install nuts and bolts securing RH front wheelhouse liner to vehicle

Note
2x nuts, 10mm, 4 Nm, 3x bolts, 10mm, 4 Nm
Install clips securing RH wheelhouse liner to vehicle

Note
7x clips
Install RH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque LH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH front wheel

Note
5x nuts, 21mm, 175 Nm
Install RH front lug nut covers

Note
5x covers
Install LH front lug nut covers

Note
5x covers
Torque LH front axle nut

Note
1x nut, 32mm, 245 Nm
Torque RH front axle nut

Note
1x nut, 32mm, 245 Nm, 1x washer
Install RH front wheel center cap

Note
1x cap, Verify emblem is aligned with valve stem
Install LH front wheel center cap

Note
1x cap, Verify emblem is aligned with valve stem
Secure the ground connection at the A/C compressor mount bracket

Note
1x bolt, T25, 7 Nm
Connect the AC compressor logic connector

Note
1x connector
Connect coolant reservoir level sensor

Note
1x connector
Install both AC lines to compressor

Note
2x nuts, 10mm, 10 Nm, Install new O-rings
Secure FDU logic connector harness clip

Note
1x clip
Connect FDU logic connector

Note
1x connector, Red locking tab
Install FDU ground strap to FDU assembly

Note
1x bolt, E10, 6 Nm
Install 12V battery beam

Note
2x bolts, T30, 3.5 Nm, 1x edge clip
Secure coolant reservoir hose to 12V battery beam

Note
1x bolt, T30, 5 Nm
Position 12V battery bracket assembly onto battery beam for installation
Install fasteners securing 12V battery bracket to shock tower cross member and the battery beam

Note
2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
Connect 12V positive terminal

Note
1x nut, 10mm, 6 Nm
Install 12V positive terminal cover
Install remaining fastener securing RH 3-way valve to subframe

Note
1x bolt, T30, 5 Nm
Release air suspension pump bracket and chiller assembly from front end carrier
Install the fasteners securing air suspension pump bracket to subframe

Note
2x bolts, 10mm, 5.5 Nm
Secure chiller assembly to subframe

Note
3x bolts, 10mm, 5 Nm
Connect the logic connectors for the steering rack

Note
2x electrical connectors, 2-way connectors, Engage the grey lock after the connector is fully seated
Install logic connector harness clip to subframe assembly

Note
1x fir tree clip
Connect steering rack connectors

Note
2x connectors, 2 stage locking connectors, Ensure the locking tab is engaged after an audible click is heard when connecting
Slide battery pump 2 onto bracket secured to front subframe

Note
Line up cut out with bracket and slide pump to the left of vehicle
Connect First Responder Loop and 12V negative terminal

Note
1x connector, 1x nut, 10mm, 5 Nm, Connect First Responder Loop first
Remove steering wheel holder from vehicle
Connect hoses to vehicle and perform A/C vacuum and leak test

Note
(Touch time only)30 minute vacuum, 10 minute leak test. Ensure quick connects are fully engaged, turn the connector dials clockwise to fully connect to A/C service ports
Push wiring harness through underhood storage unit and seat grommet

Note
1x rubber grommet
Feed harness grommet through underhood storage unit and install underhood storage unit

Note
1x grommet, Lift the underhood storage unit appropriately to access the grommet
Install bolts and clips securing underhood storage unit

Note
2x bolts, 10mm, 7 Nm, 2x push clips
Install underhood storage carpet and reconnect light and release switch connectors

Note
2x connectors, Secure edges of carpet underneath underhood storage unit seal
Install front underhood apron

Note
7x clips
Install HEPA filter outlet duct
Overlap time for A/C vacuum and leak test
Perform A/C refrigerant refill

Note
Green check mark approves, Red X declines, Run time only
Select Action 'Stop' , Fluid Fill Target 'Refrigerant' and press 'Run'

Note
This stops the fluid Fill/ Drain routine and returns the Thermal system to normal operation
Disconnect AC machine hoses from service ports

Note
2x connections, High side (red), low side (blue), Turn knob counter clockwise until fully open, Pull back on AC line lock to release from port
Install dust caps onto high-side and low-side service ports

Note
2x caps
Install HEPA filter inlet duct

Note
2x tabs, One on each side
Install clips securing HEPA filter inlet duct to cowl panel

Note
3x push clips
Secure drainage hoses to HEPA filter inlet duct

Note
2x hoses
Install LH underhood apron

Note
9x clips
Install RH underhood apron

Note
9x clips
Test A/C functions in vehicle to ensure cabin cooling functions as designed
Perform A/C hose flush

Note
Touch time only. No overlap from this since the machine is disconnected from the vehicle.
Remove coolant reservoir cap
Start Fluid Fill/Drain in Toolbox 3

Note
Go to Actions and search for PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain Click 'Fluid Fill/Drain' Under 'Action' select 'Start' Under 'Fluid Fill Target' select 'Coolant' Click 'RUN'
Fill the reservoir to the "MAX" line with the specified coolant while the "Fluid Drain and Fill" routine is running.

Note
Carefully monitor the coolant level while the routine is running, adding coolant as required
Stop Fluid Fill/Drain in Toolbox 3

Note
Go to Actions and search for PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drainclick 'Fluid Fill/Drain'. Under 'Action' select 'Stop' Under 'Fluid Fill Target' select 'Coolant' Click 'RUN'
Start coolant air purge in Toolbox 3

Note
In Toolbox 3 go to Actions and search for Coolant Air Purge click PROC_THC_X_COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Coolant Air Purge and click 'RUN'
Fill the reservoir to the "MAX" line with the specified coolant while the system is purging

Note
Carefully monitor the coolant level while the routine is running, adding coolant as required
Install coolant reservoir cap
Perform Thermal test in Toolbox 3

Note
In Toolbox 3, go to Actions and search for PROC_THC_X_THERMAL-TESTvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Thermal Test then click 'Thermal System Test', check 'Precondition' and click 'RUN' and wait for the results
Exit Service Mode

Note
Controls > Service Mode > Exit Service Mode
Disconnect Toolbox from vehicle and install cubby under MCU

Note
1x connector, 2x clips, Ensure diagnostic cables are tucked into the appropriate position then engage cubby
Move RH front seat to original position
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
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''
Close all four doors
Verify turn and slip plates are locked
Position vehicle onto 4-post lift

Note
Set ride height to standard, Position wheel chocks to keep vehicle from rolling
Raise the alignment rack and lower 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
Torque LH air spring module nut and bolt to LH aft link

Note
1x bolt, 21mm, 1x nut, 22mm, 140 Nm
Remove existing paint mark from LH air spring module bolt

Note
Clean the area thoroughly so the new marking is not confused with the previous marking
Mark LH air spring module bolt to show component has been torqued

Note
Use a high visibility paint pen when marking components
Torque RH air spring module nut and bolt to RH aft link

Note
1x bolt, 21mm, 1x nut, 22mm, 140 Nm
Remove the existing paint mark from RH air spring module

Note
Clean the area thoroughly so the new marking is not confused with the previous marking
Mark the RH air spring module bolt to show the component has been torqued

Note
Use a high visibility paint pen when marking components
Install front aero shield into position and hand tighten center bolts

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

Note
10x push clips
Install and tighten bolts securing aero shield to vehicle

Note
12x bolts, 10mm, 4 Nm
Place mid aero shield for installation
Install bolts securing mid aero shield to vehicle

Note
7x bolts, 10mm, 4 Nm
Install clips securing mid aero shield to vehicle

Note
7x push clips
Install screws and nut securing RH shear plate to vehicle

Note
1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Install new nut
Install clips securing RH shear plate to wheel fairing

Note
2x push clips
Install screws and nut securing LH shear plate to vehicle

Note
1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Install new nut
Install push clips securing LH shear plate to wheel fairing

Note
2x push clips
Lower 4-post lift fully
Remove wheel chocks
Raise all four windows
Remove vehicle from 4-post lift
Review wheel alignment requirements and add correction code as needed

Model S Service Manual

Mount - Front Drive Unit - RH (2nd Generation) (Remove and Replace)

Removal

Installation

Figure 1

Figure 2

Figure 3