17/08/2022 09:48:04

Drive Unit - Rear - Small (Remove and Install)

Correction Code 40016001

Special tools required for this procedure:

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Use the specified coolant only. In this manual, refer to Fluids.
Supplier Part Number Description
Tesla 1071308-00-B Small Drive Unit Sling
Tesla 1046674-00-C COVER, HV, INV, 3.0-150
Tesla 1498673-00-A KIT, CABLE AXLE REMOVER, MS/MX/M3
Tesla 1031106-00-A AST Fluid Pump
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Note
New small rear drive units are shipped with 1046674-00-C.

Removal

  1. Remove the rear subframe. See Small RDU.
  2. Move the subframe fixture and transmission jack to the gantry area.
  3. Place a coolant catcher under the subframe fixture.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 2 coolant hoses that are still attached to the small rear drive unit are removed as an assembly.
  4. Release the clip that attaches the coolant hoses to the rear subframe.
  5. Release the clip that attaches the low voltage harness to the coolant hoses.
  6. At the front of the small rear drive unit, remove the bolt that attaches the coolant hose bracket (torque 5.5 Nm).
  7. Plug the holes for the HV cables.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow coolant to enter the openings for the HV cables.
  8. Disconnect the 2 coolant hoses from the front LH side of the small rear drive unit.
  9. Disconnect the 2 coolant hoses from the RH side of the small rear drive unit.
  10. On each side of the rear subframe, release the 2 grommets that attach the wheel speed sensor harness.
  11. On each side of the rear subframe, remove the bolt that attaches the upper link to the knuckle (torque 140 Nm).
  12. On each side of the rear subframe, remove the bolt that attaches the toe link to the knuckle (torque 130 Nm).
  13. Position the axle remover cable around the inner joint of the LH small rear drive unit halfshaft, and then use a cable tie to hold the axle remover cable in position.
    Figure 1. Axle removed from small rear drive unit for demonstration purposes
  14. Hook the axle remover slide hammer on the 2 axle remover cable loops, and then use the slide hammer to remove the halfshaft from the small rear drive unit.
  15. Repeat the previous 2 steps to remove the RH small rear drive unit halfshaft.
  16. Remove and discard the cable tie that attaches the NVH pad to the small rear drive unit.
  17. Working from behind the small rear drive unit, release the hook-and-loop straps that attach the NVH pad.
  18. Working in front of the small rear drive unit, remove the clip that attaches the NVH pad to the LH side motor mount.
  19. Pull the NVH pad outboard to remove it.
  20. Remove the NVH pad from the LH side of the small rear drive unit:
  21. Remove the bolt that attaches the front of the small rear drive unit to the rear subframe (torque 90 Nm).
  22. Remove the bolt that attaches the rear of the small rear drive unit to the rear subframe (torque 90 Nm).
  23. Remove the 3 bolts that attach the LH side motor mount to the small rear drive unit (torque 22 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    This causes the LH side of the small rear drive unit to drop slightly.
  24. Remove the bolt that attaches the LH side motor mount to the rear subframe (torque 90 Nm).
  25. Push the LH side motor mount outboard.
  26. Attach the blue, red, and yellow sling mounts of the sling tool to the small rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    The black sling mount is not used in this procedure.
    1 Red sling mount
    2 Blue sling mount
    3 Yellow sling mount
    Informational PurposesAn informational icon, calling your attention
    Note
    When securing the yellow sling mount, use the hoist ring with the sleeve spacer.
    1 Sleeve spacer
  27. Secure the sling tool to the gantry.
  28. Lift the small rear drive unit out of the rear subframe.
  29. Set the small rear drive unit down onto a pallet, and then remove the sling tool from the gantry and from the small rear drive unit.

Installation

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all patchbolt(s).
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all nylon-insert locknuts.
  1. Attach the blue, red, and yellow sling mounts of the sling tool to the replacement small rear drive unit.
    1 Red sling mount
    2 Blue sling mount
    3 Yellow sling mount
    Informational PurposesAn informational icon, calling your attention
    Note
    When securing the yellow sling mount, use the hoist ring with the sleeve spacer.
    1 Sleeve spacer
  2. Secure the sling tool to the gantry.
  3. Lift the replacement small rear drive unit out of the shipping crate and position it into the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    When lowering the small rear drive unit into the subframe, do not align the rear mount on the small rear drive unit with the mounting hole in the rear subframe. Instead, pull the rear mount beyond the rear subframe. This provides enough clearance for the front of the small rear drive unit to rotate into position as the rear subframe is lowered.
  4. Remove the sling tool from the gantry, and from the replacement small rear drive unit.
  5. Install the bolt that secures the front of the drive unit to the rear subframe (torque 90 Nm).
  6. Install the bolt that secures the rear of the drive unit to the rear subframe (torque 90 Nm).
  7. Install the LH side motor mount to the rear subframe, and then install the bolt that attaches the motor mount to the subframe (torque 90 Nm).
  8. Raise the LH side of the small rear drive unit, and then install the 3 bolts that secure the LH side motor mount to the small rear drive unit (torque 22 Nm).
  9. Insert the fluid pump through the axle seal and fill the drive unit with 2,250 ml of the recommended fluid. Refer to Fluids.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pump fluid into the drive unit slowly.
  10. Position the NVH pad over the small rear drive unit.
  11. Fasten the clip that attaches the NVH pad to the LH side motor mount.
  12. Fasten the hook-and-loop straps that attach the NVH pad.
  13. Install a new cable tie to attach the NVH pad to the small rear drive unit.
  14. Align the LH halfshaft so that the opening in the snap ring is down, facing towards the bottom of the small rear drive unit.
  15. Insert the LH halfshaft into the small rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not damage or displace the oil seal.
  16. Carefully push the LH halfshaft into the small rear 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.
  17. 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 small rear drive unit, repeat from step 14 and then test that the halfshaft is fully seated.
  18. Repeat step 14 through 17 for the RH halfshaft.
  19. On each side of the rear subframe, install the bolt that attaches the toe link to the knuckle (torque 130 Nm).
  20. On each side of the rear subframe, install the bolt that attaches the upper link to the knuckle (torque 140 Nm).
  21. On each side of the rear subframe, fasten the 2 grommets that secure the wheel speed sensor harness.
  22. Install the 2 coolant hoses to the RH side of the small rear drive unit.
  23. Install the 2 coolant hoses to the front LH side of the small rear drive unit.
  24. Remove the plugs from the holes for the HV cables.
  25. At the front of the small rear drive unit, install the bolt that attaches the coolant hose bracket to the small rear drive unit (torque 5.5 Nm).
  26. Fasten the clip that attaches the low voltage harness to the coolant hoses.
  27. Fasten the clip that attaches the coolant hoses to the rear subframe.
  28. Remove the coolant catcher from under the subframe fixture.
  29. Return the subframe fixture and transmission jack to the work area.
  30. Carefully inspect the connector seals of the HV cables. If any are damaged, replace them.
  31. 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.
  32. Install the rear subframe. See Small RDU.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Only fully tighten the suspension bushing bolts when the vehicle is in ride height position.
  33. If both the front and rear drive units were removed at the same time, the vacuum refill tool must be used to refill the cooling system. See Cooling System - Vacuum Refill.
  34. If only the rear small rear drive unit was removed, bleed the cooling system. See Cooling System - Partial Refill and Bleed.
  35. Use the sling tool and gantry to lift the old small rear drive unit off the pallet and into the shipping crate.