01/04/2024 14:01:46

Gearbox Fluid - Rear Drive Unit (Drain and Refill)

Correction code 40300102 0.66 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.
  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. 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
  7. Remove clips securing mid aero shield
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    Note
    4x push clips
  8. Remove bolts securing mid aero shield and remove from vehicle
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    Note
    16x bolts, 10mm, 6 Nm
  9. Position oil drain container under RDU drain valve
  10. Disconnect oil pump connector
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    Note
    1x connector, Do not push down on gray tab, Pull gray tab to disengage lock, Pull again to release connector
  11. Remove fasteners from RDU oil pump
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    Note
    2x bolts, EPL10, 5 Nm + 20 degrees
  12. Remove the oil pump from the RDU
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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
  13. Remove the oil filter from RDU
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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.
  14. Remove fill plug from RDU
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    Note
    1x plug, 8mm Allen, 15 Nm
  15. 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
  16. Install new 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 + 135 degrees Lubricate seal prior to installation
  17. Reinstall RDU oil pump assembly
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    Note
    Make sure O-rings are lubricated prior to installation,
  18. Install RDU oil pump fasteners
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    Note
    2x bolts, EPL10, 5 Nm and 20 degrees
  19. Set up fill kit with KAF1 gearbox fluid.
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    Note
    Set fluid level to 2000 mL in measuring container
  20. 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
  21. Set up fill process
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    Note
    Place measured fluid container in drain basket, fully submerge input hose, prime pump with KAF1 fluid
  22. Connect the 12V power supply to RDU oil pump
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    Note
    1x connector
  23. 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
  24. 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
  25. 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
  26. Disconnect 12V power supply tool from oil pump
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    Note
    1x electrical connector
  27. Connect oil pump connector
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    Note
    1x connector, Engage locking tab
  28. Spray area with brake cleaner and wipe residual fluid off with towel
  29. 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
  30. 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
  31. Install rear underhood apron
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    Note
    11x clips, 2x datums
  32. Close hood
  33. Release IP service panel
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    Note
    4x tabs, 2x datums
  34. 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, https://toolbox.teslamotors.com, For local connection issues with Toolbox 3 refer to https://toolbox.teslamotors.com/articles/43695, Media converter box is powered by laptop using USB, Ethernet connection will provide communication
  35. Select ‘Actions/Autodiag’ tab and search for ‘ DI'
  36. Select ‘ TEST-SELF_DIF_X_OIL-PUMPvia Toolbox: (link)-PRESSURE ’, click ‘Run’, and allow routine to complete
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    Note
    If this test is failing, add additional fluid and retest. Select ‘X’ at top right of window to close once_x000A_complete
  37. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit
  38. Install IP service panel
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    Note
    4x tabs, 2 datums
  39. 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
  40. Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle
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    Note
    16x bolts, 10mm, 6 Nm
  41. Install clips securing mid aero shield
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    Note
    4x push clips
  42. 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
  43. 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.
  44. 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"