01/04/2024 14:03:27

Oil Pump - Rear Drive Unit (Long Range) (Remove and Replace)

Correction code 40304602 0.90 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.

Remove

  1. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Disconnect LV power. See LV Power (Disconnect and Connect).
  4. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  5. Position an oil drain container under the rear drive unit drain valve.
  6. Release the locking tab, and then disconnect the oil pump electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not push down on gray tab. Pull the grey tab to disengage lock, and then pull again to release the connector.
  7. Remove the bolts (x2) that attach the rear drive unit oil pump to the rear drive unit.
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  8. Remove oil pump from the rear drive unit, and allow the oil to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful when removing the pump to avoid damage to the plastic and casting.
  9. Remove the oil filter from the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    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.
  10. Remove the fill plug from the rear drive unit.
  11. Inspect O-rings and seals on the plug, oil pump (x3), and oil filter.
    • If missing an O-ring on the oil pump or seal on the oil filter, check inside the rear drive unit and remove before installation.
    • If damaged O-ring on the oil pump, replace all the O-rings (x3).
    • If damaged O-ring on plug, replace the plug.

Install

  1. Install a new rear drive unit oil filter.
    3 Nm (2.2 lbs-ft) + 135 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the seal on the new oil filter before installation.
    Informational PurposesAn informational icon, calling your attention
    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.
  2. Install the rear drive unit oil pump.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate all O-rings on new oil pump before installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully position the oil pump into the rear drive unit.
  3. Install the bolts (x2) that attach the rear drive unit oil pump to the rear drive unit.
    5 Nm (3.7 lbs-ft) + 20 degrees
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  4. Prepare the oil transfer pump.
    1. Place the oil measuring container on the drain basket, and fill the container with 2000 mL of KAF1 fluid.
    2. Place the oil transfer pump input hose in the measuring container.
    3. Prime the pump with oil.
  5. Trim both input and output hoses to 26 inches, insert the output hose into the fill hole until it is fully seated, and then pull the hose back 5mm.
  6. Fully submerge the input hose into the fill container, and then prime the pump with KAF1 fluid.
  7. Connect a 12V power supply to the oil pump.
  8. Assistance is recommended for the following steps, as they are critical to properly fill the rear drive unit to specification.
    Informational PurposesAn informational icon, calling your attention
    Note
    Have the rear drive unit fill plug ready for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    The assistant will run oil pump switchbox using XP-10 Jump Pack.
  9. Pump 5 full strokes of KAF1 fluid into the rear drive unit while simultaneously running the oil pump for the entire fill process.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not run the pump dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Keep running the oil pump switch box until drain plug is installed in next step. If the pump is not running and the drain plug is not installed, fluid will drain from plug within 10 seconds.
    Informational PurposesAn informational icon, calling your attention
    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
  10. While running the oil pump switch box, remove the hand pump from the fill hole, and then install fill plug into the rear drive unit.
    15 Nm (11.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Assistance is required. The switch box should continue to run until the system is closed.
    Tip: Use of the following tool(s) is recommended:
    • 8 mm hex
  11. Disconnect the 12V power supply tool from the oil pump.
  12. Connect the oil pump electrical connector, and then secure the locking tab.
  13. Carefully spray the drive unit with brake cleaner, and then wipe clean with a towel.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use PPE such as a face covering and protective glasses when handling brake cleaner.
  14. Lower the vehicle fully.
  15. Connect LV power. See LV Power (Disconnect and Connect).
  16. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  17. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
  18. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  19. Reinstall the vehicle software. See Firmware Reinstall - Toolbox.
  20. Click the Actions/Autodiag tab, and then search for "DI".
  21. Click TEST-SELF_DIF_X_OIL-PUMP-PRESSUREvia Toolbox: (link), click Run, and allow routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    If this test is failing, add additional fluid and retest. Select ‘X’ at top right of window to close once complete
  22. Disconnect Toolbox and remove the laptop from the vehicle.
  23. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  24. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.