08/09/2022 16:25:53

Electromechanical Brake Booster Assembly (Remove and Replace)

Correction code 33201002 1.86 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 Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

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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.

Remove

  1. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Open the LH front door.
  3. Lower the LH and RH front windows.
  4. Move the driver seat fully rearwards.
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Disconnect LV power. See LV Power (Disconnect and Connect).
  7. Clean the area around the brake fluid reservoir, and then remove the brake reservoir cap.
  8. Remove the brake fluid from the brake reservoir.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use special tool 1541474-00-B - measure & fill kit.
  9. Install the brake reservoir cap.
  10. Remove all wheels. See Wheel Assembly (Remove and Install).
  11. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  12. Remove the front underhood apron. See Underhood Apron - Front (Remove and Replace).
  13. Remove the underhood storage unit access panel. See Underhood Storage Unit Access Panel (Remove and Replace).
  14. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  15. Remove the RH wiper arm. See Wiper Arm - RH (Remove and Replace).
  16. Remove the LH wiper arm. See Wiper Arm - LH (Remove and Replace).
  17. Remove the cowl scree panel. See Panel - Cowl Screen (Remove and Replace).
  18. Remove the wiper module. See Wiper Module (Remove and Replace).
  19. Disconnect the brake booster ECU electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab, and then press the black tab and rotate the lever to release the electrical connector.
  20. Disconnect the DTS position sensor from the brake booster assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab.
  21. Put shop towels underneath the brake lines to catch any brake fluid that may leak.
  22. Disconnect the brake fluid level sensor electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the red tab to disengage the lock, and then pull again to release the electrical connector. Do not push down on the red tab.
  23. Remove the flexible brake lines (x2) from the master cylinder.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench flex head
  24. Release the locking tab, and then disconnect the remote reservoir coupling hose from the brake reservoir.
  25. Remove the LH front floor mat.
  26. Remove the driver outboard footwell cover. See Cover - Footwell - Outboard - Driver (Remove and Replace).
  27. Remove the driver inboard footwell cover. See Cover - Footwell - Inboard - Driver (Remove and Replace).
  28. Remove the driver knee airbag as an assembly from the instrument panel. However, do not remove the knee airbag cover brace from the airbag assembly. See Knee Airbag - Driver (Remove and Replace).
  29. Remove the cotter clip from the clevis pin, and then remove the clevis pin from the brake pedal assembly.
  30. Remove and discard the nuts (x2) that attach the brake booster assembly to the bulkhead.
    16.5 Nm (12.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the nuts after removal.
  31. Remove the brake booster assembly from the vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the flexible brake lines out of the way for clearance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the brake booster assembly clockwise to clear the A/C lines.

Install

  1. Install the brake booster assembly to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the flexible brake lines out of the way for clearance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Insert the pedal linkage through the bulkhead and rotate the brake booster assembly counterclockwise to clear the A/C lines and seat studs.
  2. Install new nyloc nuts (x2) that attach the brake booster assembly to the bulkhead.
    16.5 Nm (12.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new nyloc nuts.
  3. Install the clevis pin to the brake pedal assembly, and then insert the cotter clip into the clevis pin.
  4. Install the driver knee airbag. See Knee Airbag - Driver (Remove and Replace).
  5. Install the driver inboard footwell cover. See Cover - Footwell - Inboard - Driver (Remove and Replace).
  6. Install the driver outboard footwell cover. See Cover - Footwell - Outboard - Driver (Remove and Replace).
  7. Install the LH front floor mat.
  8. Install the flexible brake lines (x2) to the master cylinder.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench flex head
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the brake lines with brake cleaner before installation.
  9. Secure the remote reservoir hose to the brake reservoir.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coupling (x1). Secure the locking tab.
  10. Connect the brake fluid level sensor electrical connector.
  11. Connect the DTS position sensor to the brake booster assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the red locking tab.
  12. Connect the brake booster ECU electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the electrical connector, and then rotate the lever to fully seat.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the red locking tab.
  13. Remove the shop towels from underneath the brake lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean up any residual fluid lost.
  14. Install the wiper module. See Wiper Module (Remove and Replace).
  15. Install the cowl scree panel. See Panel - Cowl Screen (Remove and Replace).
  16. Install the RH wiper arm. See Wiper Arm - RH (Remove and Replace).
  17. Install the LH wiper arm. See Wiper Arm - LH (Remove and Replace).
  18. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  19. Remove the underhood storage unit access panel. See Underhood Storage Unit Access Panel (Remove and Replace).
  20. Remove the front underhood apron. See Underhood Apron - Front (Remove and Replace).
  21. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  22. Reconnect LV power. See LV Power (Disconnect and Connect).
  23. Bleed the brakes. See Brake Fluid Bleed/Flush (Remove and Replace).
  24. Install all wheels. See Wheel Assembly (Remove and Install).
  25. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  26. Restore the driver seat back to its original position.
  27. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors
  28. Perform a road test and ensure proper brake pedal feel and performance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Add correction code (00040100) to account for time.