04/12/2024 10:54:41

Inverter - Rear Drive Unit (Remove and Replace)

Correction code 40200602 3.30 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.

  • 2024-12-04: Updated inverter fastener torque sequence.
  • 2024-02-06: Updated gearbox fluid to KAF1.
  • 2023-07-25: Removed steps that detail the resolver error learn.
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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.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Do not service the drive unit inverter and the car computer concurrently. First, service the drive unit inverter. After installation of the drive unit inverter has completed successfully, then service the car computer.

Remove

  1. While performing the courtesy inspection, note any abnormal tire wear that could indicate the need for an alignment.
  2. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  3. Place stanchions around the rear of the vehicle to setup a safety perimeter.
  4. Release the electronic parking brake. See Park Brake Caliper - Release.
  5. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_PMR_X_STORE-DATA-BOOTvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Store Bootloader Data to store inverter bootloader data, click Run, and then allow the routine to complete.
  6. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_DIR_X_STORE-DATA-APPvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Store Application Data to store inverter application data, click Run, and then allow the routine to complete.
  7. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant 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. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  9. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  10. Disconnect LV power. See LV Power (Disconnect and Connect).
  11. 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.
  12. Remove the rear wheels. See Wheel Assembly (Remove and Install).
  13. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  14. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  15. Remove the leather glove protectors and HV insulating gloves.
  16. Remove the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  17. Remove the nut that attaches the rear drive unit ground strap to the body stud, and then remove the ground strap from the stud.
  18. Remove the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
  19. Remove the bolts (x4) that attach the rear subframe stiffener to the rear subframe, and then remove the stiffener from the subframe.
  20. Press the locking tab, raise the handle, and disconnect the rear subframe electrical harness from the logic connector, then release the clip that attaches the electrical harness to the LH side of the rear drive unit, and move the electrical harness aside.
  21. Release the clips (x2) that attach the powertrain coolant supply hose to the rear subframe.
  22. Remove bolt and nut that attach the rear drive unit HV harness to the rear drive unit.
  23. Install a wood or hard foam block to support the rear drive unit for the following steps.
  24. Remove the bolt that attaches the rear drive unit to the LH side of the rear subframe.
  25. Slide the red connector locking tab, open the black release lever, and then disconnect the rear drive unit HV harness from the rear drive unit inverter HV header.
  26. Use a pry bar to gently raise the rear drive unit to create clearance, and then remove the rear drive unit HV harness from the drive unit.
  27. Move a coolant catcher to under the rear drive unit inverter.
  28. Release the clip, disconnect the powertrain coolant supply hose from the rear drive unit inverter inlet, allow to drain, plug both fittings, and then remove the hose from the rear drive unit.
  29. Remove the screw that attaches the inverter inlet to the rear drive unit inverter, and then remove the inlet from the inverter.
  30. Release the clip, disconnect the rear drive unit inverter outlet to heat exchanger hose from the rear drive unit inverter outlet, an then immediately plug both fittings.
  31. Release the clip that attaches the rear drive unit inverter outlet to heat exchanger hose from the rear drive unit LH mount.
  32. Remove the bolts (x3) that attach the rear drive unit LH mount to the rear drive unit, and use a pry bar to gently move the rear drive unit to create clearance, and then remove the LH mount from the drive unit.
  33. Put on the ESD wrist strap and attach it to the rear drive unit inverter housing.
  34. Remove and discard the rear drive unit phase out cover label to access the bolts behind.
  35. Remove the bolts (x2) that attach the phase out cover to the rear drive unit gearbox, and then use a plastic trim tool to remove the cover from the gearbox.
  36. 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-C or newer revision, for installation.
  37. Remove and discard the bolts (x3) that attach the rear drive unit motor 3-phase terminals to the rear drive unit inverter 3-phase terminals.
  38. Remove the bolts (x12) that attach the rear drive unit inverter to the rear drive unit gearbox..
  39. Carefully remove the rear drive unit inverter from the rear drive unit gearbox, and move the inverter up and out between the rear subframe and drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the inverter circuit board when removing the inverter.
  40. Remove the plugs from the inverter and drain the coolant.
  41. Set the rear drive unit inverter onto an ESD mat, and then remove the ESD wrist strap clip from the inverter housing.
  42. Inspect the rear drive unit 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Also inspect the gearbox housing and remove any dropped fasteners or loose debris.

Install

  1. Prepare the new rear drive unit inverter and attach the ESD strap to the new inverter housing
  2. Remove the screw that attaches the inverter inlet to the new rear drive unit inverter, and then remove the inlet from the inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Retain the inlet for later installation.
  3. Use an IPA wipe to clean the phase terminals of the rear drive unit motor and the new rear drive unit inverter, and allow at least one minute to dry.
  4. Inspect the condition of the gap pad on the new rear drive unit 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.
  5. Make sure that a new gasket is installed onto the new rear drive unit inverter.
  6. Carefully install the new rear drive unit inverter in and down between the rear subframe and rear drive unit. Align the inverter to the 2 pins in the rear drive unit gearbox, and then install the inverter to the gearbox.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the inverter circuit board when installing the inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the phase terminals align during installation.
    INVERTER NONE
  7. Install and hand-tighten the bolts (x12) that attach the new front drive unit inverter to the front drive unit gearbox.
  8. Tighten the 2 bolts nearest the alignment dowels first, and then tighten the remaining bolts (x10) that attach the new front drive unit inverter to the front drive unit gearbox.
    5 Nm (3.7 lbs-ft) +20 deg
  9. Install and hand-tighten new bolts (x3) to attach the front drive unit motor 3-phase terminals to the new front drive unit inverter 3-phase terminals.
  10. Tighten the bolts (x3) that attach the front drive unit motor 3-phase terminals to the new front drive unit 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.
  11. Lightly lubricate the front drive unit 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.
  12. Install the phase out cover into the front drive unit gearbox, and then install the bolts (x2) that attach the cover to the gearbox.
    14 Nm (10.3 lbs-ft)
  13. Install a new phase out cover label.
  14. Remove the ESD wrist strap from the new inverter, attach it to the old inverter, and prepare the old inverter for shipment to MRB.
  15. Remove ESD wrist strap.
  16. Use a pry bar to gently move the rear drive unit to create clearance, install the rear drive unit LH mount to the rear drive unit, and then install the bolts (x3) that attach the mount to the drive unit.
    35 Nm (25.8 lbs-ft) +55 deg
  17. Fasten the clip that attaches the rear drive unit inverter outlet to heat exchanger hose from the rear drive unit LH mount.
  18. Remove the plugs, immediately connect the rear drive unit inverter outlet to heat exchanger hose from the rear drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  19. Install the new inverter inlet into the rear drive unit inverter, and then install the screw that attaches the inlet to the inverter.
    6 Nm (4.4 lbs-ft)
  20. Remove the plugs, connect the powertrain coolant supply hose to the rear drive unit inverter inlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  21. Move the coolant catcher out from under the rear drive unit inverter.
  22. Use a pry bar to gently raise the rear drive unit to create clearance, and then install the rear drive unit HV harness onto the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to align the stud and datum of the harness with the holes in the drive unit.
  23. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the rear drive unit inverter HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  24. Use the pry bar to position the rear drive unit, and then install the bolt that attaches the rear drive unit to the LH side of the rear subframe.
    120 Nm (88.5 lbs-ft)
  25. Remove the block from under the rear drive unit.
  26. Install bolt and nut that attach the rear drive unit HV harness to the rear drive unit.
    6 Nm (4.4 lbs-ft)
  27. Fasten the clips (x2) that attach the powertrain coolant supply hose to the rear subframe.
  28. Inspect the rear subframe electrical harness logic connector and the rear drive unit inverter logic connector for coolant, and use shop air and a clean dry shop towel to remove any coolant from the connectors.
  29. Connect the rear subframe electrical harness to the rear drive unit inverter logic connector, raise the handle upward, and fasten the locking tab, and then fasten the clip that attaches the electrical harness to the LH side of the rear drive unit.
  30. Install the rear subframe stiffener to the rear subframe, and then install the bolts (x4) that attach the stiffener to the subframe.
    120 Nm (88.5 lbs-ft)
  31. Install the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
  32. Install the rear drive unit ground strap to the body stud, and then install the nut that attaches the ground strap to the stud.
    10 Nm (7.4 lbs-ft)
  33. Install the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  34. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  35. Perform a cooling system vacuum refill. See .
  36. Connect LV power. See LV Power (Disconnect and Connect).
  37. Connect the LV maintainer and disconnect the LV battery. See .
  38. Engage the electronic parking brake. See Park Brake Caliper - Release.
  39. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:
    • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
     to return the coolant system valves to their original position, click Run, and then allow the routine to complete.
  40. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_PMR_X_RESTORE-DATA-BOOT-AND-WRITE-DRIVE-TYPEvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Bootloader Data
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Bootloader Data
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Bootloader Data
     to restore inverter bootloader data, click Run, and then allow the routine to complete.
  41. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): UPDATE_CAN-REDEPLOYvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
     to perform a service CAN redeploy, click Run, and then allow the routine to complete.
  42. Connect the LV battery and disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  43. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_DIR_X_RESTORE-DATA-APPvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Restore Application Data to restore inverter application data, click Run, and then allow the routine to complete.
  44. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
     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.
  45. Add coolant to the reservoir as necessary.
  46. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
     to check the cooling system, click Run, and then allow the routine to complete.
  47. 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.
  48. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_DIR_X_RESOLVER-ERROR-LEARNvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Resolver Error Learn, and then follow the displayed instructions.
  49. Install the rear wheels. See Wheel Assembly (Remove and Install).
  50. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  51. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  52. Hold the LH and RH B-pillar upper buttons in the Close position to manually calibrate the LH and RH falcon wing doors.
  53. Remove the stanchions from the rear of the vehicle.
  54. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.