23/05/2024 09:22:02

Inverter - LH - Rear Drive Unit (Plaid) (Remove and Replace)

Correction code 40200702 3.78 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.

  • 2024-02-06: Updated gearbox fluid to KAF1.
  • 2023-07-25: Removed steps that detail the resolver error learn.
  • 2023-04-13: Reordered steps around the before replacement dashboard.
Warning IconA warning icon, calling your attention to a possibly risky situation
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. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Place stanchions around rear of vehicle to setup safety perimeter.
  3. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  4. In Toolbox 3, click the Dashboards tab, and type ‘Inverter' into the search field.
  5. Click [Palladium S/X][Plaid] REAR-LEFT Drive INVERTER - Replacement, from the BEFORE Rear-Left Drive Inverter Replacement Action List, click PROC_PMREL_X_STORE-DATA-BOOTSearch for routine in ToolboxStore Rear Left Drive Inverter Bootloader Data before Replacementhv / Rear Left Drive Inverter Replacement - Store Bootloader Data to store inverter bootloader data, click Run, and then allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the rear drive unit RH inverter is to be replaced, click [Palladium S/X][Plaid] REAR-RIGHT Drive INVERTER - Replacement, and follow the steps accordingly.
  6. From the BEFORE Rear-Left Drive Inverter Replacement Action List, click PROC_DIREL_X_STORE-DATA-APPSearch for routine in ToolboxStore Rear Left Drive Inverter Application Data before Replacementhv / Rear Left Drive Inverter Replacement - Store Application Data to store inverter application data, click Run, and then allow the routine to complete.
  7. From the BEFORE Rear-Left Drive Inverter Replacement Action List, click PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTSearch for routine in ToolboxStart Thermal Fluid Fill/Drain (Coolant only)Thermal / Coolant System - Start Thermal Fill/Drainhv / Rear Drive Inverter Replacement - Start Fluid Fill/Drainhv / Rear Left Drive Inverter Replacement - Start Fluid Fill/Drainhv / Rear Right Drive Inverter Replacement - Start Fluid Fill/Drainhv / Front Drive Unit Replacement - Start Coolant Fill/Drainhv / Rear Drive Unit Replacement - Start Coolant Fill/DrainThermal / Actions - Start Coolant Fill/Drainhv / Front Drive Inverter Replacement - Start Fluid Fill/Drain to put the coolant system valves into position for the vacuum fill that will happen later when the vehicle is powered down, click Run, and then allow the routine to complete.
  8. Release the parking brake calipers. See Park Brake Caliper - Release.
  9. Remove the laptop with Toolbox 3 from the vehicle, but do not power off the laptop or change the Toolbox state. See Toolbox 3 (Connect and Disconnect).
  10. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  11. Disconnect LV power. See LV Power (Disconnect and Connect).
  12. Set the high voltage multimeter to DC voltage, lightly touch the probes to the auxiliary battery connector contacts, and verify that the multimeter displays a voltage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Battery voltage is typically 14.5 to 15.5 volts.
  13. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  14. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
  15. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  16. Remove the leather glove protectors and HV insulating gloves.
  17. Remove the rear wheels. See Wheel Assembly (Remove and Install).
  18. Remove the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  19. Remove the rear subframe from the vehicle. See Subframe Assembly - Rear (Plaid) (Remove and Install).
  20. Remove the rear subframe stiffener. See Stiffener - Rear Subframe (Plaid) (Remove and Replace).
  21. Release the clips (x4) that attach the rear subframe harness to the rear of the subframe.
  22. Release the connector gray locking tab, and then disconnect the rear subframe electrical harness from the rear oil pump connector.
  23. Position the subframe lift underneath the gantry.
  24. Install an additional shackle to the blue and red cables, and then use the hooks (x3) to attach the drive unit sling tool to the rear drive unit.
  25. Attach the drive unit sling tool to the gantry.
  26. Use the gantry to raise the drive unit sling tool so that there is slight tension in the cables.
  27. Remove the bolt that attaches the rear drive unit to the LH side of the rear subframe.
  28. Remove the bolt that attaches the rear drive unit to the RH side of the rear subframe.
  29. Remove the bolt that attaches the rear drive unit to the rear of the rear subframe.
  30. Partially raise the rear drive unit so that the inverters just clear the rear beam of the rear subframe.
  31. Slide the red connector locking tab, open the black release lever, and then disconnect the rear drive unit LH HV harness from the LH inverter of the rear drive unit.
  32. Release the clips (x2), disconnect the coolant hoses (x2) from the rear drive unit LH inverter, and then immediately plug the fittings (x4).
  33. Release the clips (x2) that attach the coolant hoses to the rear drive unit LH inverter.
  34. Release the clip, and then disconnect the electrical harness from the rear drive unit LH inverter LV connector.
  35. Put on the ESD wrist strap and attach the clip to the rear drive unit LH inverter housing.
  36. Puncture the phase out cover label to access the bolts behind.
    Informational PurposesAn informational icon, calling your attention
    Note
    The label and cover are one time use.
  37. Remove the bolts (x2) that attach the phase out cover to the rear drive unit LH gearbox, and then use a plastic trim tool to remove the cover from the gearbox..
  38. Inspect the condition of the phase out cover and O-rings. If the cover has less than 6 O-rings, or if the O-rings or cover are damaged, discard the cover and use a new cover, part 1096984-00-D or newer revision, for installation.
  39. Remove the bolts (x3) that attach the rear drive unit LH motor 3-phase terminals to the rear drive unit LH inverter 3-phase terminals.
  40. Remove the bolts (x12) that attach the rear drive unit LH inverter to the rear drive unit LH gearbox, and then remove the inverter from the gearbox.
  41. Remove the plugs from the inverter and drain the coolant.
  42. Set the rear drive unit LH inverter onto an ESD mat, and then remove the ESD wrist strap clip from the inverter housing.
  43. Inspect the rear drive unit LH gearbox housing to make sure that there is no gap pad stuck there. If there is, remove the gap pad, clean the area with an alcohol wipe, and allow at least one minute to dry.

Install

  1. Attach the ESD wrist strap clip to the new rear drive unit LH inverter housing.
  2. Use an IPA wipe to clean the phase terminals of the rear drive unit LH motor and the new rear drive unit LH inverter, and allow at least one minute to dry.
  3. Inspect the condition of the gap pad on the rear drive unit LH inverter PCB. Replace the gap pad if it does not fulfill these criteria:
    • New and undamaged condition.
    • Fully covers the discharge resistor array and no resistors are visible.
    • Clean and free of debris.
    • Evenly adhered to the inverter PCB.
  4. Install a new gasket onto the rear drive unit LH inverter.
  5. Carefully align the rear drive unit LH inverter to the 2 pins in the rear drive unit LH gearbox, and then install the inverter to the gearbox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the phase terminals align during installation.
  6. Install and hand-tighten the bolts (x12) that attach the rear drive unit LH inverter to the rear drive unit LH gearbox.
  7. Tighten the bolts (x12) that attach the rear drive unit LH inverter to the rear drive unit LH gearbox in the sequence shown.
    12.5 Nm (9.2 lbs-ft)
  8. Install and hand-tighten the bolts (x3) that attach the rear drive unit LH motor 3-phase terminals to the rear drive unit LH inverter 3-phase terminals.
  9. Tighten the bolts (x3) that attach the rear drive unit LH motor 3-phase terminals to the rear drive unit LH inverter 3-phase terminals.
    11.5 Nm (8.5 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If any bolts are dropped into the gearbox housing, they must be retrieved.
    Informational PurposesAn informational icon, calling your attention
    Note
    If installing a new bolt, tighten to 12.5 Nm, back off 180 degrees, then torque to 5 Nm +40 degrees.
  10. Lightly lubricate the rear drive unit LH gearbox phase out cover bores with KAF1 fluid, and if a new phase out cover is to be installed, lightly lubricate the O-rings of the cover.
  11. Install the phase out cover into the rear drive unit LH gearbox, and then install the bolts (x2) that attach the cover to the gearbox.
    14 Nm (10.3 lbs-ft)
  12. Perform the inverter air leak test. See Inverter Air Leak Test (On Table).
  13. Install a new phase out cover label.
  14. Attach the ESD wrist strap onto the old inverter.
  15. Place the old inverter into an ESD bag, and then into the ESD return box.
  16. Remove the ESD wrist strap.
  17. Fasten the clip, and then connect the electrical harness to the rear drive unit LH inverter LV connector.
  18. Fasten the clips (x2) that attach the coolant hoses to the rear drive unit LH inverter.
  19. Remove the plugs from the fittings (x4), immediately connect the coolant hoses (x2) to the rear drive unit LH inverter, and then fasten the clips (x2).
  20. Verify that the black release lever of the rear drive unit LH HV harness connector is in the open position, install the connector flat and square to the rear drive unit LH inverter HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  21. Lower the rear drive unit sling tool so as to install and hand tighten the bolt that attaches the rear drive unit to the rear of the rear subframe.
  22. Install and hand tighten the bolt that attaches the rear drive unit to the RH side of the rear subframe.
  23. Install and hand tighten the bolt that attaches the rear drive unit to the LH side of the rear subframe.
  24. Lower the drive unit sling tool to release tension in the cables, and then remove the sling tool from the gantry.
  25. Remove the hooks (x3), and then remove the drive unit sling tool from the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the extra shackles on the blue and red cables.
  26. Tighten the rear drive unit mount bolts (x3).
    120 Nm (88.5 lbs-ft)
    213 Nm (157.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque E18 120 Nm, torque EP20 213 Nm.
  27. Connect the rear subframe electrical harness to the rear oil pump connector, and then fasten the connector gray locking tab.
  28. Fasten the clips (x4) that attach the rear subframe harness to the rear of the subframe.
  29. Install the rear subframe stiffener. See Stiffener - Rear Subframe (Plaid) (Remove and Replace).
  30. Install the rear subframe into the vehicle. See Subframe Assembly - Rear (Plaid) (Remove and Install).
  31. Install the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  32. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
  33. Perform a vacuum refill. See Cooling System (Vacuum Refill).
  34. Connect LV power. See LV Power (Disconnect and Connect).
  35. Connect the LV maintainer and disconnect the LV battery. See LV Maintainer (Connect and Disconnect).
  36. Engage the electronic parking brake. See Park Brake Caliper - Release.
  37. If necessary, re-establish the Toolbox 3 connection to the vehicle. See Toolbox 3 (Connect and Disconnect).
  38. In Toolbox 3, from the AFTER Rear-Left Drive Inverter Replacement Action List, click PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINSearch for routine in ToolboxStop Thermal Fluid Fill/DrainThermal / Refrigerant System - Stop Thermal Fill/DrainThermal / Coolant System - Stop Thermal Fill/Drainhv / Front Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Rear Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Rear Left Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Rear Right Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Front Drive Unit Replacement - Stop Coolant Fill/Drainhv / Rear Drive Unit Replacement - Stop Coolant Fill/DrainThermal / Actions - Stop Thermal Fill/Drain to return the coolant system valves to their original position, click Run, and then allow the routine to complete.
  39. From the AFTER Rear-Left Drive Inverter Replacement Action List, click PROC_PMREL_X_RESTORE-DATA-BOOTSearch for routine in ToolboxRestore REAR-LEFT Drive INVERTER Bootloader Data after Replacement to restore inverter bootloader data, click Run, and then allow the routine to complete.
  40. From the AFTER Rear-Left Drive Inverter Replacement Action List, click UPDATE_CAN-REDEPLOYSearch for routine in ToolboxService CAN Redeployhv / Drive Inverter DIRE1L Replacement - CAN Redeployhv / Drive Inverter DIRE1R Replacement - CAN Redeployhv / Drive Inverter DIRE2 Replacement - CAN Redeployhv / Front Drive Inverter Replacement - CAN Redeployhv / Rear Drive Inverter Replacement - CAN Redeployhv / Rear Left Drive Inverter Replacement - CAN Redeployhv / Rear Right Drive Inverter Replacement - CAN Redeployhv / Front Drive Unit Replacement - CAN Redeployhv / Rear Drive Unit Replacement - CAN Redeploy to perform a service CAN redeploy, click Run, and then allow the routine to complete.
  41. Connect the LV battery and disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  42. From the AFTER Rear-Left Drive Inverter Replacement Action List, click PROC_DIREL_X_RESTORE-DATA-APPSearch for routine in ToolboxRestore Rear Left Drive Inverter Application Data after Replacementhv / Rear Left Drive Inverter Replacement - Restore Application Data to restore inverter application data, click Run, and then allow the routine to complete.
  43. From the AFTER Rear-Left Drive Inverter Replacement Action List, click TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start to purge air from the cooling system, click Run, and then allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    The routine may take up to 10 minutes to complete.
  44. Add coolant to the reservoir as necessary.
  45. From the AFTER Rear-Left Drive Inverter Replacement Action List, click TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCESearch for routine in ToolboxThermal System Performance TestThermal / Actions - Test Thermal Performancehv / Front Drive Inverter Replacement - Thermal System Testhv / Rear Drive Inverter Replacement - Thermal System Testhv / Rear Left Drive Inverter Replacement - Thermal System Testhv / Rear Right Drive Inverter Replacement - Thermal System Testhv / Front Drive Unit Replacement - Thermal System Testhv / Rear Drive Unit Replacement - Thermal System Test to check the cooling system, click Run, and then allow the routine to complete.
  46. Manually engage the hood latch.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the hood is open, or if the hood latch is not manually engaged, the vehicle speed will be limited and the resolver learn routine will fail.
  47. From the Rear-Left Resolver Learn Action List, click Palladium S/X INVERTER-resolver error learn, click Run Network, and then follow the displayed instructions.
  48. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  49. Install the rear wheels. See Wheel Assembly (Remove and Install).
  50. On the vehicle touchscreen, open the hood to disengage the hood latch.
  51. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  52. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  53. Hold the LH and RH B-pillar upper buttons in the Close position to manually calibrate the LH and RH falcon wing doors.
  54. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  55. Perform a four wheel alignment check, and adjust if necessary. See Four Wheel Alignment Check.