25/10/2023 03:28:37

Seal - Axle - Rear Drive Unit - LH (Plaid) (Remove and Replace)

Correction code 40301012 1.02 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.

2023-10-25: Updated EPB Service Mode reference.

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
Prepare to raise vehicle, 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.
Use Toolbox to place the vehicle into EPB Service Mode. See Park Brake Caliper - Release - Toolbox.
Remove LH rear wheel center cap.

Note
1x cap.
Loosen the LH rear axle nut.

Note
1x nut, 32mm, 245 Nm.
Loosen LH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Raise vehicle partially and lower 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 LH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Disconnect EPB harness connector to the LH caliper motor.

Note
1x connector, Disengage locking tab then release connector.
Release subframe harness from LH rear active dampener.

Note
2x connectors, 1x grommet.
Release harness clip from LH rear knuckle.

Note
1x clip.
Remove wheel speed sensor from LH rear knuckle .

Note
1x bolt, T30, 5 Nm.
Release connector to LH rear ANC sensor.

Note
1x connector, Disengage red locking tab and push down on black tab to release.
Remove bolts securing LH rear knuckle harness bracket and move aside.

Note
2x bolts, T30, 5 Nm, Move harness aside with bracket.
Release LH rear brake hose from LH rear lower aft link.

Note
1x bolt, 10mm, 6 Nm.
Release LH rear stabar link from rear stabar assembly.

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal.
Remove LH rear brake caliper from LH rear knuckle and hang from body.

Note
2x bolts, E18, 125 Nm, Hang caliper from body if not fully removing, Route caliper hose so that it does not get caught on stabar assembly.
Remove axle nut and discard washer securing LH rear drive axle to hub assembly.

Note
If washers are not present, procure a set so they can be installed later in this procedure.

Note
1x nut, 32mm, 245 Nm.
If installed, remove and discard the bolt that attaches the brake rotor to the hub.
Note
A new bolt will not be installed.
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Install the hub puller onto the LH rear brake rotor.

Note
5x lug nuts, 21mm, Hand tight.
Use hub puller to free LH rear halfshaft from hub splines.
Remove hub puller from LH rear hub assembly.

Note
5x lug nuts, 21mm, Hand tight.
Remove rotor from LH rear knuckle.
Remove nut securing LH rear air spring module to LH rear knuckle.

Note
1x nut, 21mm, 150 Nm, Do not remove the bolt.
Remove bolt securing LH rear upper fore link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm.
Remove bolt securing LH rear toe link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm.
Remove bolt securing LH rear lower fore link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm.
Remove bolt securing LH rear upper aft link to knuckle.

Note
1x bolt, 21mm, 150 Nm.
Remove bolt securing LH rear lower aft link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm.
Remove LH rear knuckle assembly from vehicle.

Note
Recommend assistance, Support knuckle as needed, Remove bolt holding knuckle to air strut and remove knuckle assembly.
Release LH inboard CV joint from RDU and remove from vehicle.

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing, If oil cooler is present (Performance), place towel on oil cooler to protect during removal and install.
Remove LH rear output seal.

Note
1x output seal.

Install

Install LH rear output seal.

Note
1x output seal, Verify seal is fully seated.
Position halfshaft into vehicle for installation.

Note
Ensure snap-ring is installed on halfshaft assembly, If oil cooler is present (Performance), place towel on oil cooler to protect during removal and install.
Install LH inboard CV joint into RDU.

Note
Recommend assistance, Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Carefully push the halfshaft into the drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
Apply Molykote M-77 to outboard side of LH axle shaft.

Note
Clean if necessary, Apply no more than 1 gram to axle only.
Position LH rear knuckle for installation.

Note
Recommend assistance, Place knuckle into vehicle for installation, If required, use a bolt or punch to temporarily hold knuckle in place, Remove pin punch when fasteners for the links are ready to be installed.
Install bolt securing LH rear lower aft link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and secure flag nut, Torque at later step.
Install bolt securing LH rear toe link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and secure flag nut, Torque at later step.
Install bolt securing LH lower fore link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Use a pry bar to help align fastener hole to knuckle, Insert bolt and secure flag nut, Torque at later step.
Install bolt securing LH upper fore link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and secure flag nut, Torque at later step.
Install bolt securing LH rear upper aft link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Insert bolt and thread in fully, Torque at later step.
Install bolt securing LH rear air spring module to LH rear knuckle.

Note
1x bolt, 21mm, 150 Nm, Pry upwards on valve body to align fastener holes, Use deadblow as a leverage against the upper arms and knuckle, Use shop towel and prevent marring on the air spring module, Line up air spring module with knuckle, Torque at later step.
Position rotor onto LH rear knuckle.
Install hub jack adapter onto LH rear hub.

Note
5x lug nuts, 21mm, Hand tight, Use modified hydraulic hub tool if correct adapter is not available.
Position and raise support stand to simulate LH rear suspension at ride height.
Measure the distance from the upper fore link to the bolt on the frame rail to make sure LH suspension is set to ride height.

Note
Distance should be 85mm +/- 5mm.
Torque bolt securing LH rear lower aft link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Mark with paint pen.
Torque bolt securing LH rear toe link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Mark with paint pen.
Torque bolt securing LH rear lower fore link to knuckle.

Note
1x bolt, 21mm, 170 Nm, Mark with paint pen.
Torque bolt securing LH rear upper fore link to knuckle.

Note
1x bolt, 1x flag nut, 21mm, 150 Nm, Mark with paint pen.
Torque bolt securing LH rear upper aft link to knuckle.

Note
1x bolt, 21mm, 150 Nm, Mark with paint pen.
Remove support stand from underneath LH rear suspension.

Note
Lower stand until suspension is unladen before removal.
Remove hub jack adapter from LH rear hub.

Note
5x lug nuts, 21mm, Hand tight.
Install axle nut and new washer assembly.

Note
1x nut, 32mm, 245 Nm. Torque at later step.
Install LH rear brake caliper to knuckle.

Note
2x bolts, E18, 125 Nm, Remove S-hook.
Secure LH rear stabar link to stabar assembly.

Note
1x nyloc nut, 15mm, 55 Nm, Install new nut, Counter-hold ball joint with 5mm hex, Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link.
Route and install bolts securing LH rear knuckle harness bracket .

Note
2x bolts, T30, 5 Nm, Route into place and secure.
Secure connector to LH rear ANC sensor.

Note
1x connector, Engage red locking tab.
Install wheel speed sensor to LH rear knuckle .

Note
1x bolt, T30, 5 Nm.
Secure harness clip onto LH rear knuckle.

Note
1x clip.
Secure subframe harness to LH rear active dampener.

Note
2x connectors, 1x grommet.
Connect LH EPB caliper harness connector.

Note
1x connector, Fully seat connector then engage locking tab.
Install LH rear wheel.

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool.
Lower vehicle until tires are touching the ground.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Torque LH rear wheel.

Note
5x nuts, 21 mm, 175 Nm.
Torque LH rear axle nut.

Note
1x nut, 32mm, 245 Nm.
Install LH rear wheel center cap.

Note
1x cap, Verify emblem is aligned with valve stem.
Hold brake pedal and select park on UI to disable EPB service mode.
Remove vehicle from lift.

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".
Raise LH front window.
Close LH front door.
Verify turn and slip plates are locked.
Set vehicle ride height to Standard, then drive vehicle onto alignment rack and shift into Park.

Note
Recommend assistance for aligning vehicle to ramps.
Open LH front door.
Lower LH front window.
Exit vehicle and place wheel chocks around driver's rear wheel.
Latch seat belt to driver buckle.
Set steering wheel straight ahead.
Enter vehicle, enable Jack Mode, shift to neutral, then close driver's door latch.

Note
Make sure climate control and headlights are off as well.
Raise 4-post lift and lower 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.
Set tire machine pressures to match vehicle.

Note
Refer to the "Tire and Loading Information" label located on the driver side B-pillar.
Install pressure hoses onto all four wheels so tire pressures can be set automatically.

Note
Pull hose from reel and lock into position, then remove valve stem cap and install hose onto valve stem.
Install alignment heads onto all four wheels.

Note
Position alignment heads near the center of the wheel, Adjust side arms as necessary to grip tires securely.
Check that front turn plates are centered on tires.

Note
Adjust turn plate location if necessary.
Perform rolling compensation.

Note
Push vehicle forward using driver's side rear tire, Insert wheel chocks once vehicle has been rolled forward, Turn and slip plates should automatically unlock.
Apply brake pedal depressor.
Perform caster sweep, then center steering wheel per level bubble and lock steering wheel into position.
Print vehicle alignment summary.

Note
Include before/after results.
Remove alignment heads from all four wheels.
Lower 4-post lift fully.
Remove brake pedal depressor, steering wheel level, and steering wheel holder and place vehicle into Park.
Use exterior door handle to release driver door latch.
Remove wheel chocks.
Raise LH front window.
Close LH front door.
Remove vehicle from 4-post lift.

Note
Release seat belt from driver buckle, Remove suspension from Jack Mode, Return lights to Auto mode.