05/04/2024 15:26:30

Oil Pump - Front Drive Unit (Remove and Replace)

Correction code 39301602 0.72 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.

  • 2024-04-05: Updated gearbox fluid information with link.
  • 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. 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 front aero shield.
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    Note
    5x push clips.
  8. Remove bolts securing front aero shield and remove from vehicle.
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    Note
    9x bolts, 10mm, 6 Nm.
  9. Release clips securing wheel house liner to front skid plate.
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    Note
    4x clips.
  10. Remove bolts securing front skid plate to body sill.
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    Note
    2x bolts, 15mm, 30 Nm.
  11. Remove bolts securing front skid plate to body casting.
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    Note
    2x bolts, 15mm, 60 Nm.
  12. Remove bolts securing front skid plate to front subframe and remove skid plate.
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    Note
    4x bolts, 15mm, 70 Nm.
  13. Position the oil drain under oil pump area.
  14. Disconnect the FDU oil pump connector.
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    Note
    1x electrical connector, Disengage locking tab, then release connector.
  15. Remove bolts securing oil pump to the FDU.
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    Note
    2x bolts, EP10, 5 Nm + 20 degrees .
  16. Remove oil pump from FDU.
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    Note
    Pry the pump away from the FDU with a pry tool or flat blade screwdriver on both tabs, Ensure the FDU casting is not damaged, Allow the oil to drain from the FDU.
  17. Position foldable funnel under oil filter .
  18. Remove oil filter from FDU.
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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 counterclockwise, 3 Nm and 135 degrees, Allow oil to drain.
  19. Remove fill plug from FDU.
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    Note
    1x plug, 8mm Allen, 15 Nm.

Install

  1. 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.
  2. Install new 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 seals prior to installation.
  3. Remove foldable funnel from subframe .
  4. Install oil pump into FDU.
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    Note
    Use residual oil in the oil pump cavity to lubricate the seals of the oil pump before installation, Align bolt holes with housing.
  5. Install bolts securing oil pump to FDU.
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    Note
    2x bolts, EP10, 5 Nm + 20 degrees.
  6. Set up fill kit with new gearbox fluid.
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    Note
    Refer to Fluids to determine which gearbox fluid is applicable.
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    Note
    Set fluid level to 2000 mL in measuring container.
  7. 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.
  8. Set up fill process.
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    Note
    Place measured fluid container in drain basket, fully submerge input hose, and prime the pump with new gearbox fluid.
  9. Connect 12V power supply to oil pump.
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    Note
    1x connector.
  10. Pump the new gearbox fluid into the front drive unit.
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    Note
    Assistant required, Pump 5 full strokes from fluid container, then run pump via switch box for entire fill and keep running until drain plug installed, Do not run pump when dry, If pump is not running and drain plug not installed fluid will drain from plug within 10 seconds.
  11. Install fill plug into the FDU.
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    Note
    1x plug, 8mm Allen, 15 Nm.
  12. Disconnect 12V power supply tool from oil pump.
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    Note
    1x electrical connector.
  13. Connect the oil pump connector.
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    Note
    1x electrical connector, Fully seat connector, then engage locking tab.
  14. Spray area with brake cleaner and wipe residual fluid off with towel.
  15. Torque bolts securing front skid plate to body casting.
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    Note
    2x bolts, 15mm, 60 Nm.
  16. Torque bolts securing front skid plate to body sill.
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    Note
    2x bolts, 15mm, 30 Nm.
  17. Torque bolts securing front skid plate to front subframe.
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    Note
    4x bolts, 15mm, 70 Nm,.
  18. Secure clips securing wheel house liner to front skid plate.
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    Note
    4x clips.
  19. Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle.
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    Note
    9x bolts, 10mm, 6 Nm.
  20. Install clips securing front aero shield.
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    Note
    5x push clips.
  21. Lower vehicle until tires are touching the ground.
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  22. 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.
  23. Perform a service CAN redeploy. See Firmware Reinstall - Toolbox.
  24. Install rear underhood apron.
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    Note
    11x clips, 2x datums.
  25. Close hood.
  26. 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".