01/04/2024 14:02:05

Heat Exchanger - Rear Drive Unit (Long Range) (Remove and Replace)

Correction code 40305202 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.
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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 vehicle.
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    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.
  2. Open hood.
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    Note
    Via center display > Controls > Frunk Open.
  3. Remove rear underhood apron.
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    Note
    11x clips, 2x datums.
  4. Power off vehicle via center display.
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    Note
    Controls > Safety & Security > Power Off.
  5. Disconnect LV battery connector and First Responder Loop.
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    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL.
  6. Remove RH underhood apron.
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    Note
    11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
  7. Remove LH underhood apron.
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    Note
    11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
  8. Remove front underhood apron.
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    Note
    12x clips, 3 datums.
  9. Remove frunk access panel.
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    Note
    3x clips, 3x hooks, 1x connector.
  10. Remove frunk carpet.
  11. Remove frunk assembly.
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    Note
    8x bolts, 10mm, 5 Nm .
  12. Raise vehicle fully and lower lift onto locks.
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    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.
  13. Remove clips securing mid aeroshield.
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    Note
    4x push clips.
  14. Remove bolts securing mid aeroshield and remove from vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  15. Disconnect oil pump connector.
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    Note
    1x connector, Pull grey tab to disengage lock then disconnect.
  16. Remove clips securing RH side of subframe harness to RDU.
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    Note
    2x clips.
  17. Position coolant drain underneath RH rear of vehicle.
  18. Disconnect PT return hose from RDU heat exchanger.
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    Note
    1x spring clip, Plug hose and heat exchanger as needed.
  19. Remove clip securing PT return hose to RDU heat exchanger.
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    Note
    1x clip.
  20. Disconnect inverter to oil cooler hose from RDU heat exchanger.
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    Note
    1x spring clip, Plug hose and heat exchanger as needed.
  21. Remove clip securing inverter to oil cooler hose to RDU heat exchanger.
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    Note
    1x clip.
  22. Remove bolts securing heat exchanger to rear drive unit.
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    Note
    2x bolts, EP10, 5 Nm and 30 degrees.
  23. Remove RDU heat exchanger.
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    Note
    Do not pry against RDU or heat exchanger, Damage may occur, It may be necessary to gently work heat exchanger up and down to free it from RDU, Do not allow coolant to enter RDU oil passages, Prevent cross-contamination.

Install

  1. Position RDU heat exchanger.
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    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 RDU oil passages, Prevent cross-contamination.
  2. Install bolts securing heat exchanger to rear drive unit.
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    Note
    2x bolts, EP10, 5 Nm and 30 degrees.
  3. Install clip securing inverter to oil cooler hose to RDU heat exchanger.
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    Note
    1x clip.
  4. Install inverter to oil cooler hose onto RDU heat exchanger.
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    Note
    1x spring clip, Remove plugs from both ends of each coolant connection, Perform push-pull-push test to make sure hose is fully seated.
  5. Install clip securing PT return hose to RDU heat exchanger.
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    Note
    1x clip.
  6. Install PT return hose onto RDU heat exchanger.
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    Note
    1x spring clip, Remove plugs from both ends of each coolant connection, Perform push-pull-push test to make sure hose is fully seated.
  7. Remove coolant drain container from underneath vehicle.
  8. Position oil drain container under RDU drain valve.
  9. Remove fill plug from RDU.
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    Note
    1x plug, 8mm allen, 15 Nm.
  10. Remove fasteners securing RDU oil pump.
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    Note
    2x bolts, EP10, 5 Nm and 20 degrees.
  11. Remove RDU oil pump assembly.
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    Note
    Pry the pump away from the RDU, Be cautious when prying to avoid damage to plastic and casting, Allow the oil to drain from the RDU.
  12. Remove RDU oil filter.
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    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.
  13. Inspect seals and O-rings.
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    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.
  14. Install RDU oil filter.
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    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.
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    Note
    Spin clockwise, 3 Nm and 135 degrees, Lubricate seal prior to installation.
  15. Install RDU oil pump assembly.
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    Note
    Inspect O-rings for damage and verify none are stuck inside the drive unit casting, Replace O-rings if necessary, Lightly coat O-rings with clean fluid.
  16. Install fasteners securing RDU oil pump.
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    Note
    2x bolts, EP10, 5 Nm and 20 degrees.
  17. Set up fill kit with KAF1 gearbox fluid.
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    Note
    Set fluid level to 2000 mL in measuring container.
  18. Install fluid transfer pump.
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    Note
    Trim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm.
  19. Set up fill process.
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    Note
    Place measured fluid container in drain basket, fully submerge input hose, prime pump with fluid.
  20. Connect the 12V power supply to RDU oil pump.
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    Note
    1x connector, Engage locking tab.
  21. Recommend assistance for following steps as they are critical to properly fill RDU to spec.
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    Note
    Assistant will run oil pump switchbox using XP-10 Jump Pack and have RDU fill plug ready for installation.
  22. Pump KAF1 fluid into rear drive unit.
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    Note
    Assistant required, Do not run pump dry, Pump 5 full strokes from fluid container, While simultaneously running oil pump switch box for entire fill process. Keep running oil pump switch box until drain plug is installed in next step, If pump is not running and drain plug is not installed fluid will drain from plug within 10 seconds. Note: The minimum refill capacity of the rear drive unit assembly is 2.1 liters. Using excess gearbox fluid in the fill container allows the oil pump to dispense the full 2.1 L without drawing air. Make sure that there is less than 200mL left when completed.
  23. Continue running oil pump switch box, Remove hand pump from fill hole and Install fill plug into RDU.
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    Note
    1x plug, 8mm Allen, 15 Nm, Assistance required, The switch box should continue to be ran until the system is closed.
  24. Disconnect 12V power supply from RDU oil pump.
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    Note
    1x connector.
  25. Install clips securing RH side of subframe harness to RDU.
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    Note
    2x clips.
  26. Connect oil pump connector.
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    Note
    1x connector, Engage locking tab.
  27. Spray area with brake cleaner and wipe residual fluid off with towel.
  28. Remove oil drain container from underneath vehicle.
  29. Apply Loctite 222 onto mid aeroshield bolts and install fasteners securing mid aeroshield to vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  30. Install clips securing mid aeroshield.
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    Note
    4x push clips.
  31. Lower vehicle fully.
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  32. Remove coolant bottle cap.
  33. Inspect coolant level and top off as necessary.
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    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required.
  34. Connect First Responder Loop and LV battery connector.
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    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.
  35. Release IP service panel.
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    Note
    4x tabs, 2x datums.
  36. Using laptop connect to vehicle with ethernet diag kit and Toolbox 3.
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    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.
  37. Select "Actions/Autodiag" tab and search for "Purge".
  38. Select 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, click "Run", and allow routine to complete.
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    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.
  39. Select "Actions/Autodiag" tab and search for "Low Pressure Test".
  40. Select TEST-SELF_DIR_X_OIL-PUMPSearch for routine in ToolboxOil Pump Communication Test - Rear-PRESSURE, click "Run", and allow routine to complete.
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    If this test is failing then add additional fluid and retest, Select "X" at top right of window to close once complete.
  41. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit.
  42. Install IP service panel.
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    Note
    2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP.
  43. Inspect coolant level and top off as necessary.
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    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required.
  44. Install coolant bottle cap.
  45. Install frunk assembly.
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    Note
    8x bolts, 10mm, 5 Nm.
  46. Install frunk carpet.
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    Note
    Verify carpet is properly seated under the seal.
  47. Install frunk access panel.
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    Note
    3x clips, 3x hooks, 1x connector.
  48. Install front underhood apron.
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    Note
    12x clips, 3x datums.
  49. Install LH underhood apron.
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    Note
    11x clips, 2 datums.
  50. Install RH underhood apron.
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    Note
    11x clips, 2x datums.
  51. Install rear underhood apron.
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    Note
    11x clips, 2x datums.
  52. Close hood.
  53. Calibrate the rear doors.
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    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
  54. Remove vehicle from lift.
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    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".