01/04/2024 14:01:56

Heat Exchanger - Front Drive Unit (Remove and Replace)

Correction code 39301002 1.44 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.

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

Raise and support vehicle.

Note
Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads, DO NOT position the lift arm pads under the battery or side rails, as shown in red.
Open hood.

Note
Via center display > Controls > Frunk Open.
Remove rear underhood apron.

Note
11x clips, 2x datums.
Remove RH underhood apron.

Note
11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
Remove LH underhood apron.

Note
11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
Remove front underhood apron.

Note
12x clips, 3 datums.
Remove frunk access panel.

Note
3x clips, 3x hooks, 1x connector.
Remove frunk carpet.
Remove frunk assembly.

Note
8x bolts, 10mm, 5 Nm .
Power off vehicle via center display.

Note
Controls > Safety & Security > Power Off.
Disconnect LV battery connector and First Responder Loop.

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL.
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 front aero shield.

Note
5x push clips.
Remove bolts securing front aero shield and remove from vehicle.

Note
9x bolts, 10mm, 6 Nm.
Release clips securing wheel house liner to front skid plate.

Note
4x clips.
Remove bolts securing front skid plate to body sill.

Note
2x bolts, 15mm, 30 Nm.
Remove bolts securing front skid plate to body casting.

Note
2x bolts, 15mm, 60 Nm.
Remove bolts securing front skid plate to front subframe and remove skid plate.

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm.
Disconnect the FDU oil pump connector.

Note
1x electrical connector, Disengage locking tab, then release connector.
Release the indicated inverter coolant hose clips from FDU.

Note
2x clips.
Release front oil pump harness clip from heat exchanger.

Note
1x clip.
Position foldable funnel under front drive unit.

Note
Prevent coolant contamination to HV battery components.
Position coolant drain container under the front of the vehicle to catch vehicle coolant.
Release powertrain return hose from heat exchanger.

Note
1x hose clip, Plug both ends, Allow any excess fluid to drain.
Release FDU inverter hose from heat exchanger.

Note
1x hose clip, Plug both ends as needed, .
Remove foldable funnel from subframe .
Release bolts securing FDU heat exchanger .

Note
2x bolts, EP10, 5 Nm + 30 degrees.
Remove FDU heat exchanger.

Note
2x O-rings.

Install

Install FDU heat exchanger.

Note
Lightly coat O-rings with clean KAF1 gearbox fluid, Do not pinch or deform O-ring during install, Ensure heat exchanger is fully seated, Do not allow coolant to enter FDU oil passages, Prevent cross-contamination.
Install bolts securing heat exchanger to FDU.

Note
2x bolts, EP10, 5 Nm + 30 degrees, .
Secure FDU inverter hose onto heat exchanger.

Note
1x hose clip, Remove any plugs, Perform push-pull-push test.
Secure powertrain return hose onto heat exchanger.

Note
1x hose clip, Remove any plugs, Perform push-pull-push test.
Secure front oil pump harness clip onto heat exchanger.

Note
1x clip.
Secure coolant hose clip onto heat exchanger.

Note
2x clips.
Remove coolant drain container from underneath vehicle.
Position foldable funnel under oil filter .
Position the oil drain under oil pump area.
Remove bolts securing oil pump to the FDU.

Note
2x bolts, EP10, 5 Nm + 20 degrees .
Remove oil pump from FDU.

Note
Pry the pump away from the FDU with a pry tool or flat blade screwdriver on both tabs, Ensure the FDU casting is not damaged, Allow the oil to drain from the FDU.
Remove oil filter from FDU.

Note
Tesla recommends that the oil filter is replaced with a new one upon removal. Any oil filter with visible corrosion or leaks must be replaced.

Note
Spin counterclockwise, 3 Nm and 135 degrees, Allow oil to drain.
Remove fill plug from FDU.

Note
1x plug, 8mm Allen, 15 Nm.
Inspect seals and o-rings.

Note
Inspect o-rings on removed parts, 3 o-rings on pump, one o-ring on fill plug, if missing o-ring on pump ensure it is not left in housing, if damaged o-ring on plug replace affected plug, Replace all o-rings on oil pump if damaged, Check seal on oil filter, if missing check if still on housing and remove before install.
Install new oil filter.

Note
Tesla recommends that the oil filter is replaced with a new one upon removal. Any oil filter with visible corrosion or leaks must be replaced.

Note
Spin clockwise, 3 Nm and 135 degrees, Lubricate seals prior to installation.
Remove foldable funnel from subframe .
Install oil pump into FDU.

Note
Use residual oil in the oil pump cavity to lubricate the seals of the oil pump before installation, Align bolt holes with housing.
Install bolts securing oil pump to FDU.

Note
2x bolts, EP10, 5 Nm + 20 degrees.
Set up fill kit with KAF1 gerabox fluid.

Note
Set fluid level to 2000 mL in measuring container.
Install fluid transfer pump.

Note
Trim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm.
Set up fill process.

Note
Place measured fluid container in drain basket, fully submerge input hose, prime pump with fluid.
Connect 12V power supply to oil pump.

Note
1x connector.
Pump fluid into FDU.

Note
Assistant required, Pump 5 full strokes from fluid container, then run pump via switch box for entire fill and keep running until drain plug installed, Do not run pump when dry, If pump is not running and drain plug not installed fluid will drain from plug within 10 seconds, Pump in 1.8L of fluid, Leftover fluid should be less that 200 mL.
Install fill plug into the FDU.

Note
1x plug, 8mm Allen, 15 Nm.
Disconnect 12V power supply tool from oil pump.

Note
1x electrical connector.
Connect the oil pump connector.

Note
1x electrical connector, Fully seat connector, then engage locking tab.
Spray area with brake cleaner and wipe residual fluid off with towel.
Remove oil drain container.
Position front skid plate for installation and thread in all bolts .

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 15mm, 60 Nm, 2x bolts, 15mm, 30 Nm, 2x bolts, 10mm, 10 Nm, Torque at later step.
Torque bolts securing front skid plate to body casting.

Note
2x bolts, 15mm, 60 Nm.
Torque bolts securing front skid plate to body sill.

Note
2x bolts, 15mm, 30 Nm.
Torque bolts securing front skid plate to front subframe.

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm.
Secure clips securing wheel house liner to front skid plate.

Note
4x clips.
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle.

Note
9x bolts, 10mm, 6 Nm.
Install clips securing front aero shield.

Note
5x push clips.
Lower vehicle fully.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Remove coolant bottle cap.
Inspect coolant level and top off as necessary.

Note
Ensure that the fluid level is at the Max line, Top off fluid as required.
Connect First Responder Loop and LV battery connector.

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated.
Release IP service panel.

Note
4x tabs, 2x datums.
Using laptop connect to vehicle with ethernet diag kit and Toolbox 3.

Note
Open Toolbox 3 website and establish connection to the vehicle. Media converter box is powered by laptop using USB, Ethernet connection will provide communication.
Select "Actions/Autodiag" tab and search for "Purge".
Select Coolant Air PurgeTEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEGen3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE Model3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGELow Voltage Controllers Low Voltage ControllersThermal / Actions - Coolant Air PurgeService Mode Service Plus Factory Mode Developer Thermal / Coolant System - Coolant Air PurgeService Mode Service Plus Factory Mode Developer hv / Procedures - Transport Service Plus Developer , click "Run", and allow routine to complete.

Note
Make sure vehicle is not in drive state, Routine is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required.
Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit.
Inspect coolant level and top off as necessary.

Note
Ensure that the fluid level is at the Max line, Top off fluid as required.
Install coolant bottle cap.
Install IP service panel.

Note
2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP.
Install frunk assembly.

Note
8x bolts, 10mm, 5 Nm.
Install frunk carpet.

Note
Verify carpet is properly seated under the seal.
Install frunk access panel.

Note
3x clips, 3x hooks, 1x connector.
Install front underhood apron.

Note
12x clips, 3x datums.
Install LH underhood apron.

Note
11x clips, 2 datums.
Install RH underhood apron.

Note
11x clips, 2x datums.
Install rear underhood apron.

Note
11x clips, 2x datums.
Close hood.
Calibrate the rear doors.

Note
If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
Remove vehicle from lift.

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".