26/07/2023 16:58:53

Drive Unit - Front (2nd Generation) (Remove and Install)

Correction Code 39013101

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1090880-00-A or 1090880-01-A Steering Wheel Holder (Hunter or Beissbarth)
Tesla 1066521-00-A Powertrain Table
Tesla 1096075-00-A Hydraulic Hub Puller
Tesla 1498673-00-A Axle Remover Cable Kit
Tesla 1122937-00-A Cooling Hose Service Plug Kit
Tesla 1081765-01-B Transmission Jack
Tesla 1494178-00-A MS/MX Raven FDU Cradle
This procedure is for vehicles built after April 24, 2019. For vehicles built through April 24, 2019, see Drive Unit - Front (1st Generation) (Remove and Install).

Remove

  1. Raise and support the vehicle on a 2-post lift. See Raise Vehicle - 2 Post Lift .
  2. Recover the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue this procedure until the A/C refrigerant recovery is complete.
  3. 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.
  4. Move the front passenger seat fully forward.
    Informational PurposesAn informational icon, calling your attention
    Note
    Note the position of the seat prior to move so that it will be returned back to its original position after this procedure is completed.
  5. Remove the rear center underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  6. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  7. Remove the front underhood apron. See Underhood Apron - Front (Remove and Replace) .
  8. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  9. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  10. Remove the underhood storage carpet. See Carpet - Underhood Storage (Remove and Install) .
  11. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  12. Disconnect 12V power. See Disconnect 12V Power .
  13. Remove the A/C recovery lines from the vehicle.
  14. Release the bolts (x3) that attach the chiller assembly to the front subframe assembly.
  15. Release the battery pump 2 off the mounting bracket by sliding the pump to the right of the vehicle.
  16. 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.
  17. Disconnect the electrical connectors (x2) for the logic for the steering rack.
  18. Release the fir tree clip that attaches the logic harness connector to the front subframe assembly.
  19. Remove the bolts (x2) that attach the air suspension pump bracket to the front subframe assembly.
  20. Secure the air suspension pump bracket and the chiller assembly to the front end carrier using bungee cords or similar.
  21. Loosen, but do not remove, the RH bolt that attaches the 3-way valve.
  22. Remove the 12V auxiliary battery. See Battery - Auxiliary - 12V (Remove and Replace) .
  23. Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  24. Disconnect the coolant reservoir level sensor electrical connector.
  25. Disconnect the A/C compressor logic electrical connector.
  26. Remove the bolt that attaches the ground connector at the A/C compressor mounting bracket.
  27. Remove the nuts (x2) that attach the A/C lines to the compressor.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Remove and discard the O-rings at the A/C lines, and then put new O-rings during reinstallation.
  28. Remove the bolt that attaches the ground strap to the front drive unit assembly.
  29. Release the locking tab, and then disconnect the logic connector at the front drive unit assembly.
  30. Remove the LH and RH front lug nut covers from the front wheels using the wheel nut cover removal tool.
  31. Remove the LH and RH front wheel center caps from the vehicles using a suction cup clamp.
  32. Loosen the LH and RH front axle nuts, but do not remove them yet (torque 245 Nm).
  33. Loosen, but do not remove at this time, the LH and RH front lug nuts (torque 175 Nm).
  34. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift .
  35. Remove the LH and RH front wheels.
  36. 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 1. RH tie rod
    Figure 2. LH tie rod
  37. Remove the RH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace) .
  38. Raise the vehicle fully. See Raise Vehicle - 2 Post Lift .
  39. Remove the mid aero shield. See Panel - Aero Shield - Mid (Remove and Replace) .
  40. Remove the front extrusion bash plate. See Bash Plate - Front - Extrusion (Remove and Replace) .
  41. Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install) .
  42. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace) .
  43. Remove the front subframe skid bar. See Skid Bar - Front Subframe (Remove and Replace) .
  44. Remove the front bash plate stamping. See Bash Plate - Front - Stamping (Remove and Replace) .
  45. Remove the front skidplate. See Skidplate - Front (Remove and Replace) .
  46. Remove the bolt that attaches the RH front strut to the front lower aft link. Repeat this step on the LH front strut.
    Figure 3. RH side
    Figure 4. LH side
  47. 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.
  48. 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.
  49. 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.
  50. 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.
  51. 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 5. LH shown, RH similar
  52. 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.
  53. Remove the forward bolt that attaches the RH 3-way valve to the subframe bracket.
  54. Remove the bolts (x2) that attach the LH stay bar to the front subframe assembly. Repeat this step on the RH stay bar.
  55. Remove the nuts (x2) that attach the ABS pump to the front subframe, and then release the ABS pump from the rubber mounting grommet.
  56. Put the coolant drain container under the LH corner of the vehicle to catch any coolant during the next step.
  57. Disconnect the front drive unit inlet hose, and then plug both openings with hose plugs.
  58. 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.
  59. 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.
  60. Move the coolant drain container to the RH corner of the vehicle to catch any coolant during the next step.
  61. 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.
  62. Remove the coolant drain container from under the vehicle.
  63. Remove and discard the bolts (x4) that attach the Front Junction Box (FJB)-to-front drive unit HV harness to the FJB.
  64. Disconnect the A/C HV cable from the FJB.
  65. Position the powertrain table with the Model S/X subframe adapter installed under the front of the vehicle.
  66. Connect shop air supply to the powertrain table.
  67. Raise the powertrain table 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.
  68. Remove and discard the bolts (x4) that attach the bumper carrier to the front subframe assembly.
    Figure 6. LH side
    Figure 7. RH side
  69. 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 8. LH side
  70. Remove the LH rear bolt that attaches the front subframe assembly to the body. Repeat this step on the RH rear bolt.
    Figure 9. LH side
    Figure 10. RH side
  71. 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.
  72. Partially lower the vehicle partially.
  73. Remove the LH and RH front axle nuts, and remove and discard the washers.
  74. Install the hydraulic hub puller on the LH front brake rotor using 2 lug nuts and 2 hydraulic hub puller washers.
  75. Separate the LH halfshaft from the hub splines using the hydraulic hub puller, and then remove the puller from the hub.
  76. Remove the LH halfshaft from the hub assembly.
  77. Install the axle removal tool around the inner joint of the halfshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a cable tie to secure the axle removal tool in place.
    Figure 11. Close-up view of axle removal tool on halfshaft
  78. Remove the halfshaft from the front drive unit using the axle removal tool, and then remove the halfshaft from the vehicle.
  79. Repeat step 74 - 78 on the RH halfshaft.
  80. Position the front drive unit stand and underhoist stand under the vehicle.
  81. Remove the bolts (x2) that attach the LH front drive unit mount to the body.
  82. Remove the bolts (x2) that attach the RH front drive unit mount to the body.
  83. Use the transmission jack and the MS/X drive unit cradle to lower the front drive unit assembly out of the vehicle.

Installation

  1. Position the front drive unit assembly under the vehicle for installation.
  2. Use the transmission jack and the MS/X drive unit cradle to raise the front drive unit assembly into the vehicle.
  3. Hand-tighten the bolts (x2) that attach the LH front drive unit mount to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    The LH front drive unit mount bolts will be tightened to specifications later in this procedure (torque 65 Nm).
  4. Raise the front drive unit until the RH mount bolt holes are aligned, and then hand-tighten the bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    The RH front drive unit mount bolt will be tightened to specifications later in this procedure (torque 120 Nm).
  5. Install the bolts (x2) that attach the RH front drive unit mount to the body (torque 120 Nm).
  6. Tighten the bolts (x2) that attach the LH front drive unit mount to the body (torque 65 Nm).
  7. Lower the front drive unit stand and the underhoist stand away from the front drive unit assembly.
  8. Install the LH halfshaft into the front drive unit assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the halfshaft is fully seated into the front drive unit. An audible click is heard when the C-clip is fully engaged.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage or displace the oil seal.
  9. Apply no more than 1 gram of Molykote M-77 lubricant paste only to the hub mating face on the outboard side of the halfshaft.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply any lubricant to the halfshaft splines. If lubricant is mistakenly applied, wipe the splines clean with a shop towel.
  10. Verify that the halfshaft is fully seated:
    • 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.
  11. Install the LH halfshaft into the hub, and then hand-tighten the nut and a new washer.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut can be reused.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tightening of the nut will be done a later step.
  12. Repeat steps 9 - 12 on the RH halfshaft.
  13. Put the front subframe assembly with the powertrain table under the vehicle for installation.
  14. 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.
  15. 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
  16. 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.
  17. 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
  18. Lower the powertrain table, and then remove it from under the vehicle.
  19. Disconnect the shop air supply from the powertrain table.
  20. Connect the A/C HV cable to the FJB.
  21. Install new bolts (x4) that attach the Front Junction Box (FJB)-to-front drive unit HV harness to the FJB.
  22. Put the coolant drain container under the LH front corner of the vehicle to catch any coolant during the next step.
  23. Remove the hose plugs, and then connect the front drive unit inlet hose.
  24. 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.
  25. Remove the hose plug, and then secure the hose clip and the fir tree clip that attach the coolant hose to the radiator inlet.
  26. Remove the coolant drain container from under the vehicle.
  27. 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).
  28. 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
  29. 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).
  30. 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).
  31. 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).
  32. 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).
  33. 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
  34. Install the front subframe skid bar. See Skid Bar - Front Subframe (Remove and Replace) .
  35. Install the front skidplate. See Skidplate - Front (Remove and Replace) .
  36. Install the front bash plate stamping. See Bash Plate - Front - Stamping (Remove and Replace) .
  37. 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).
  38. 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.
  39. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  40. Install the HV battery assembly. See HV Battery (RWD/AWD) (Remove and Install) .
  41. Install the front extrusion bash plate. See Bash Plate - Front - Extrusion (Remove and Replace) .
  42. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace) .
  43. Lower the vehicle partially.
  44. 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
  45. 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).
  46. Install the RH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace) .
  47. Install the bolt that attaches the ground connector at the A/C compressor mounting bracket (torque 7 Nm).
  48. Connect the A/C compressor logic electrical connector.
  49. Connect the coolant reservoir level sensor electrical connector.
  50. Install new O-rings, and then install the nuts (x2) that attach the A/C lines to the compressor (torque 10 Nm).
  51. Install the clip that secures the front drive unit logic connector harness.
  52. Connect the logic connector at the front drive unit assembly.
  53. Install the bolt that attaches the ground strap to the front drive unit assembly (torque 6 Nm).
  54. Install the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  55. Install the 12V auxiliary battery, but do not connect the negative battery terminal at this time. See Battery - Auxiliary - 12V (Remove and Replace) .
  56. Install the RH bolt that attaches the 3-way valve to the front subframe assembly.
  57. Release the bungee cords that attach the air suspension pump bracket and the chiller assembly to the front end carrier.
  58. Install the bolts (x2) that attach the air suspension pump bracket to the front subframe assembly (torque 5.5 Nm).
  59. Install the bolts (x3) that attach the chiller assembly to the front subframe assembly (torque 5 Nm).
  60. Connect the electrical connectors (x2) for the logic for the steering rack.
  61. Install the fir tree clip that attaches the logic harness connector to the front subframe assembly.
  62. Connect the steering rack electrical connectors (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    The electrical connectors feature 2-stage locking: Make sure that the locking tab is engaged after an audible click is heard when each steering rack electrical connector is connected.
  63. Slide the battery pump 2 into the mounting bracket that is attached to the front subframe assembly.
  64. Connect the First Responder Loop and the 12V battery negative terminal (torque 5 Nm).
  65. Recharge the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue this procedure until the A/C refrigerant recharge is complete.
  66. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  67. Install the underhood storage carpet. See Carpet - Underhood Storage (Remove and Install) .
  68. Install the front underhood apron. See Underhood Apron - Front (Remove and Replace) .
  69. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  70. Disconnect the A/C refrigerant high side and the low side hoses from the vehicle, and then install the dust caps on the service ports.
  71. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  72. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  73. Test the climate control in the vehicle to make sure that it functions as designed.
  74. Update the vehicle firmware. See Firmware Update.
  75. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  76. Unlock the vehicle gateway. See Gateway Unlock.
  77. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Actions - Coolant Air Purge, click Run, and allow the routine to complete.
  78. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  79. Remove the steering wheel holder from the vehicle.
  80. Restore the front passenger seat back to its original position.
  81. Install the rear center underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  82. Close the hood.
  83. Remove the vehicle from the 2-post lift.
  84. Perform a four wheel alignment. See Four Wheel Alignment Check and Adjust (Air Suspension).
  85. Install the mid aero shield. See Panel - Aero Shield - Mid (Remove and Replace) .
  86. Perform a test drive.