04/12/2024 10:44:05

Inverter - Front Drive Unit (Remove and Replace)

Correction code 39200602 5.16 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.
  • 2024-10-10: Updated the clevis mount to isolator mount torque spec.
  • 2024-04-05: Updated gearbox fluid information with link.
  • 2024-02-06: Updated gearbox fluid to KAF1.
  • 2023-08-01: Added steps to remove and install NVH cover.
  • 2023-07-25: Updated resolver error learn step.
  • 2023-06-13: Replaced Toolbox 3 routines with Touchscreen UI steps.
Warning IconA warning icon, calling your attention to a possibly risky situation
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. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Place stanchions around rear of vehicle to setup safety perimeter.
  3. Remove the wheel center cap or lug nut covers from the LH and RH front wheels.
  4. Loosen, but do not remove, the lug nuts (x5) that attach the LH and RH front wheels to their respective hubs.
  5. On the touchscreen, enable service mode. See Service Mode (Enable and Disable).
  6. On the touchscreen, touch Controls (vehicle icon) > Service > Wiper Service Mode to raise the windshield wipers to service positions.
  7. Unlock the gateway. See Gateway (Unlock).
  8. Enable Service Mode Plus. See Service Mode Plus.
  9. On the touchscreen, touch High Voltage Procedures, and under Drive-Inverter-Replacement, touch Front Drive Inverter Replacement.
  10. On the touchscreen, under Before Inverter Replacement, touch Store Bootloader Data, press and release the brake pedal, touch Run, allow the routine to complete, and then touch Close.
  11. Under Before Inverter Replacement, touch Store Application Data, press and release the brake pedal, touch Run, allow the routine to complete, and then touch Close.
  12. Under Before Inverter Replacement, touch Start Fluid Fill/Drain, touch Run, allow the routine to complete, and then touch Close.
  13. Set the steering wheel straight ahead, place a protector sheet onto the driver seat, and then install the steering wheel lock.
  14. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  15. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  16. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  17. Disconnect LV power. See LV Power (Disconnect and Connect).
  18. 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.
  19. Remove the wiper module. See Wiper Module (Remove and Replace).
  20. Remove the LH and RH front wheels. See Wheel Assembly (Remove and Install).
  21. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  22. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  23. Remove the leather glove protectors and the HV insulating gloves.
  24. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  25. Remove the front skid plate. See Skidplate - Front (Remove and Replace).
  26. Remove the bolt that attaches the steering column intermediate shaft to the steering rack input shaft.
  27. Slide the steering column intermediate shaft up and off of the steering rack input shaft.
  28. Release the clips (x4) that attach the front drive unit inverter to heat exchanger hose to the front drive unit.
  29. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform the next steps concurrent with A/C refrigerant recovery.
  30. Pull the red tab, and then pull the red tab again to disconnect the electrical harness from the A/C compressor logic connector.
  31. Release the clip that attaches the electrical harness to the A/C compressor HV harness bracket.
  32. Remove the bolt that attaches the ground strap to the A/C compressor, and then remove the ground strap from the compressor.
  33. Remove the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
  34. Slide the black locking tab, press the release, and disconnect the HV harness from the A/C compressor HV header.
  35. Release the HV heat pump bracket tab, rotate the HV heat pump bracket rearward and upward to release the bracket from the A/C compressor eyelet.
  36. Move the HV heat pump bracket out from under the A/C compressor discharge pipe, and then move to the LH side.
  37. Release the clip that attaches the coolant hose to the A/C compressor bracket.
  38. Slide the powertrain coolant pump away from the A/C compressor, and off of the A/C compressor lower bracket.
  39. Remove and discard the rear drive unit phase out cover label to access the bolts behind.
  40. Remove the bolts (x2) that attach the phase out cover to the front drive unit gearbox, and then use a plastic trim tool to remove the cover from the gearbox.
  41. 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.
  42. Remove the bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals.
  43. After the A/C refrigerant recovery has finished, disconnect the A/C hoses from the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not continue this procedure until the A/C refrigerant recovery has completed.
  44. Remove the bolt that attaches the Supermanifold to A/C compressor lines to the Supermanifold, and then disconnect the lines from the Supermanifold.
  45. With the help of an assistant, remove the bolts (x2) that attach the A/C compressor bracket to the multi-system beam, and then remove the A/C compressor out from under the multi-system beam and out of the vehicle.
  46. Remove the nut that attaches the Supermanifold to HVAC line to the Supermanifold plate.
  47. Remove the bolts (x2) that attach the Supermanifold to HVAC lines to the HVAC assembly, and then separate the lines from the HVAC assembly.
  48. Place a clean shop towel under the Supermanifold plate, and then remove the Supermanifold to HVAC lines from the Supermanifold plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the lines rearward until the stud clears the Supermanifold plate.
  49. Move the Supermanifold to HVAC lines around the coolant reservoir and out of the vehicle.
  50. Remove the bolt that attaches the front drive unit ground strap to the LH body casting.
  51. Remove the bolt that attaches the front drive unit ground strap to the front drive unit, and then remove the ground strap from the vehicle.
  52. Setup and tighten ratchet straps so that the multi-system beam supports the LH side of the front drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the straps do not route over air suspension lines, coolant hoses, or electrical harnesses.
  53. Remove the bolts (x2) that attach the LH clevis mount to the LH isolator mount.
  54. Remove the bolts (x2) that attach the LH clevis mount to the LH frame rail.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pry bar between the steering rack and front drive unit to help with bolt removal.
  55. Remove the bolts (x3) that attach the LH isolator mount to the front drive unit, and then remove the isolator mount from the drive unit.
  56. Move a coolant catcher under the LH front of the vehicle.
  57. Release the clip, disconnect the front drive unit inverter to heat exchanger hose from the front drive unit inverter outlet, and then immediately plug both fittings.
  58. Release the clip, disconnect the front drive unit inverter inlet hose from the front drive unit inverter, and then immediately plug both fittings.
  59. Release the fir tree clip that attaches the front drive unit inverter inlet hose to the front drive unit inverter.
  60. Release the locking tab, push the handle downward, and then disconnect the front subframe electrical harness from the front drive unit inverter logic connector.
  61. Release the clip that attaches the front subframe electrical harness to the front drive unit inverter.
  62. Remove the bolt that attaches the front drive unit HV harness bracket to the front drive unit inverter.
  63. Slide the red locking tab, raise the black handle, disconnect the front drive unit HV harness from the front drive unit inverter HV header,and then set the HV harness aside.
  64. Remove the brush clips (x2) that attach the front drive unit inverter cover to the front drive unit inverter, and then remove the cover from the inverter.
  65. Put on the ESD wrist strap and attach it to the front drive unit inverter housing.
  66. Remove the bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox..
  67. Carefully remove the front drive unit inverter from the front drive unit gearbox, and move the inverter up and out between the fan module and the multi-system beam.
    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.
  68. Remove the plugs from the inverter and drain the coolant.
  69. Remove and discard the bolt that attaches the 55 degree fluid coupling to the front drive unit inverter, remove the coupling from the inverter, and then set the coupling aside.
  70. Set the front drive unit inverter onto an ESD mat, and then remove the ESD wrist strap clip from the inverter housing.
  71. Inspect the front 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 and discard the bolt that attaches the straight fluid coupling to the new front drive unit inverter, and then remove the coupling from the inverter.
  3. Wet the 55 degrees fluid coupling O-ring with coolant, install the fluid coupling into the new front drive unit inverter, and then install a new bolt to attach the coupling to the inverter.
    6 Nm (4.4 lbs-ft)
  4. Use an IPA wipe to clean the phase terminals of the front drive unit motor and the new front drive unit inverter, and allow at least one minute to dry.
  5. Inspect the condition of the gap pad on the new front 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.
  6. Make sure that a new gasket is installed onto the new front drive unit inverter..
  7. Carefully move the front drive unit inverter down and in between the fan module and the multi-system beam. Align the inverter to the 2 pins in the front 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.
  8. Install and hand-tighten the bolts (x12) that attach the new front drive unit inverter to the front drive unit gearbox.
  9. 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.
    12.5 Nm (9.2 lbs-ft)
  10. Install and hand-tighten the bolts (x3) that attach the front drive unit motor 3-phase terminals to the new front drive unit inverter 3-phase terminals.
    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.
  11. 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)
    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.
  12. Lightly lubricate the front drive unit gearbox phase out cover bores with new gearbox fluid, and if a new phase out cover is to be installed, lightly lubricate the O-rings of the cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids to determine which gearbox fluid is applicable.
  13. 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)
  14. Install a new phase out cover label.
  15. Remove the ESD wrist strap from the new inverter, attach it to the old inverter, and prepare the old inverter for shipment to MRB.
  16. Remove ESD wrist strap.
  17. Perform an inverter air leak test. See Inverter Air Leak Test (In Vehicle).
  18. Install the front drive unit inverter cover to the front drive unit inverter, and then install the brush clips (x2) that attach the cover to the inverter.
  19. Verify that the black release lever of the front drive unit HV harness connector is in the open position, install the connector flat and square to the front drive unit inverter HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  20. Install the bolt that attaches the front drive unit HV harness bracket to the front drive unit inverter.
    10 Nm (7.4 lbs-ft)
  21. Fasten the clip that attaches the front subframe electrical harness to the front drive unit inverter.
  22. Connect the front subframe electrical harness to the front drive unit inverter logic connector, raise the handle upward, and fasten the locking tab.
  23. Fasten the fir tree clip that attaches the front drive unit inverter inlet hose to the front drive unit inverter.
  24. Remove the plugs from the fittings, immediately connect the front drive unit inverter inlet hose to the front drive unit inverter, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  25. Remove the plugs from the fittings, immediately connect the front drive unit inverter to heat exchanger hose to the front drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  26. Move the coolant catcher out from under the vehicle.
  27. Install the LH isolator mount to the front drive unit, install and hand-tighten the bolts (x3) that attach the isolator mount to the drive unit.
  28. Tighten the front side bolts (x2) that attach the isolator mount to the drive unit.
    35 Nm (25.8 lbs-ft) +55 deg
    Informational PurposesAn informational icon, calling your attention
    Note
    The third bolt is torqued in a later step.
  29. Install the LH clevis mount to the LH isolator mount, and then install and hand-tighten the bolts (x2) that attach the clevis mount to the isolator mount.
  30. Install and hand-tighten the bolts (x2) that attach the LH clevis mount to the LH frame rail.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pry bar between the steering rack and front drive unit to help with bolt installation.
  31. Tighten the forward bolt that attaches the clevis mount to the frame rail.
    65 Nm (47.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The rearward bolt is tightened in a later step.
  32. Tighten the bolts (x2) that attach the LH clevis mount to the LH isolator mount.
    92 Nm (67.8 lbs-ft)
  33. Tighten the rear bolt that attaches the LH isolator mount to the front drive unit.
    35 Nm (25.8 lbs-ft) +55 deg
  34. Tighten the rearward bolt that attaches the LH clevis mount to the LH frame rail.
    65 Nm (47.9 lbs-ft)
  35. Fasten the clips (x4) that attach the front drive unit inverter to heat exchanger hose to the front drive unit.
  36. Slide the steering column intermediate shaft down and onto the steering rack input shaft.
  37. Install the bolt that attaches the steering column intermediate shaft to the steering rack input shaft.
    30 Nm (22.1 lbs-ft)
  38. Install the front skid plate. See Skidplate - Front (Remove and Replace).
  39. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  40. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  41. Install the front drive unit ground strap to the front drive unit, and then install the bolt that attaches the ground strap to the drive unit.
    6 Nm (4.4 lbs-ft)
  42. Install the front drive unit ground strap to the LH body casting, and then install the bolt that attaches the ground strap to the body casting.
    15 Nm (11.1 lbs-ft)
  43. Install new O-rings onto the Supermanifold to HVAC lines, and wet the O-rings with refrigerant oil.
  44. Move the Supermanifold to HVAC lines in and around the coolant reservoir.
  45. Install the Supermanifold to HVAC lines to the HVAC assembly, and then install the bolts (x2) that attach the lines to the HVAC assembly.
    22 Nm (16.2 lbs-ft)
  46. Place a clean shop towel under the Supermanifold plate, and then install the Supermanifold to HVAC lines into the Supermanifold plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the lines rearward so that the stud clears the Supermanifold plate, then insert the lines into the plate.
  47. Install the nut that attaches the Supermanifold to HVAC line to the Supermanifold plate.
    27 Nm (19.9 lbs-ft)
  48. With the help of an assistant, install the A/C compressor in under the multi-system beam, and then install and hand-tighten the bolts (x2) that attach the A/C compressor bracket to the multi-system beam.
  49. Tighten the bolts (x2) that attach the A/C compressor bracket to the multi-system beam.
    31 Nm (22.9 lbs-ft)
  50. Install the Supermanifold to A/C compressor lines to the Supermanifold, and then install the bolt that attaches the lines to the Supermanifold.
    22 Nm (16.2 lbs-ft)
  51. Perform the A/C vacuum and run leak test. See A/C Refrigerant (Recovery and Recharge).
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform the next steps concurrent with A/C vacuum and run leak test.
  52. Slide the powertrain coolant pump onto the A/C compressor lower bracket toward the A/C compressor.
  53. Fasten the clip that attaches the coolant hose to the A/C compressor bracket.
  54. Move the HV heat pump bracket in to under the A/C compressor discharge pipe.
  55. Rotate the HV heat pump bracket rearward and down to hook the bracket onto the A/C compressor eyelet, and then rotate the HV heat pump bracket down and against the A/C compressor.
  56. Connect the HV harness from the A/C compressor HV header, and then slide the black locking tab.
  57. Install the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
    9 Nm (6.6 lbs-ft)
  58. Install the ground strap to the A/C compressor, and then install the bolt that attaches the ground strap to the compressor.
    7 Nm (5.2 lbs-ft)
  59. Fasten the clip that attaches the electrical harness to the A/C compressor HV harness bracket.
  60. Connect the electrical harness to the A/C compressor logic connector, and then push the red tab to secure the connector.
  61. Remove the ratchet strap supporting the LH side of the front drive unit from the multi-system beam.
  62. Recharge the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform the next steps concurrent with A/C refrigerant recharge.
  63. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  64. When the A/C refrigerant recharge completes, disconnect the A/C machine from the vehicle. See A/C Refrigerant (Recovery and Recharge).
  65. Connect LV power. See LV Power (Disconnect and Connect).
  66. Connect the LV maintainer and disconnect the LV battery. See LV Maintainer (Connect and Disconnect).
  67. Remove the steering wheel lock and remove the protector sheet from the driver seat.
  68. If necessary, enable Service Mode, unlock the gateway, and enable Service Mode Plus. See Service Mode (Enable and Disable), Gateway (Unlock), and Service Mode Plus.
  69. If necessary, on the touchscreen, touch High Voltage Procedures, and under Drive-Inverter-Replacement, touch Front Drive Inverter Replacement.
  70. On the touchscreen, under After Inverter Replacement, touch Stop Fluid Fill/Drain, touch Run, allow the routine to complete, and then touch Close.
  71. Under After Inverter Replacement, touch Restore Bootloader Data, press and release the brake pedal, touch Run, allow the routine to complete, and then touch Close.
  72. Under After Inverter Replacement, touch CAN Redeploy, touch Run, allow the routine to complete, and then touch Close.
  73. Connect the LV battery and disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  74. Under After Successful Redeploy, touch Restore Application Data, press and release the brake pedal, touch Run, allow the routine to complete, and then touch Close.
  75. Under After Inverter Replacement, touch Heatpump Commissioning, touch Run, allow the routine to complete, and then touch Close.
  76. Under After Successful Redeploy, touch Coolant Air Purge, touch Run, allow the routine to complete, and then touch Close.
  77. Under After Successful Redeploy, touch Thermal System Test, touch Run, allow the routine to complete, and then touch Close.
  78. Add coolant to the reservoir as necessary.
  79. 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.
  80. Under After Successful Redeploy, touch Resolver Error Learn, read the instructions displayed, touch Run, follow the instructions, allow the routine to complete, and then touch Close.
  81. Install the LH and RH front wheels. See Wheel Assembly (Remove and Install).
  82. On the vehicle touchscreen, open the hood to disengage the hood latch.
  83. Install the wiper module. See Wiper Module (Remove and Replace).
  84. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  85. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  86. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  87. On the touchscreen, touch Controls (vehicle icon) > Service > Calibrate Doors > Calibrate Doors to calibrate the rear doors.
  88. On the touchscreen, touch Controls (vehicle icon) > Service > Wiper Service Mode to disable wiper service mode.
  89. Disable Service Mode Plus. See Service Mode Plus.
  90. Disable Service Mode. See Service Mode (Enable and Disable).
  91. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  92. Remove the stanchions from around the rear of vehicle.
  93. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.