01/04/2024 14:02:02

Heat Exchanger - Rear Drive Unit - LH (Plaid) (Remove and Replace)

Correction code 40305212 1.26 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.

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
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.
Open hood.

Note
Via center display > Controls > Frunk Open.
Remove rear underhood apron.

Note
11x clips, 2x datums.
Remove RH underhood apron.

Note
11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
Remove LH underhood apron.

Note
11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
Remove front underhood apron.

Note
12x clips, 3 datums.
Remove frunk access panel.

Note
3x clips, 3x hooks, 1x connector.
Remove frunk carpet.
Remove frunk assembly.

Note
8x bolts, 10mm, 5 Nm .
Power off vehicle via center display.

Note
Controls > Safety & Security > Power Off.
Disconnect LV battery connector and First Responder Loop.

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL.
Verify operation of multimeter.

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals.
Raise vehicle fully and lower lift 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 clips securing mid aeroshield.

Note
4x push clips.
Remove bolts securing mid aeroshield and remove from vehicle.

Note
16x bolts, 10mm, 6 Nm.
Remove all items from pockets and ensure not wearing metal items.
Inspect HV insulating gloves.

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves.
Release LH RDU HV harness from HV battery.

Note
1x connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up.
Verify no high voltage at LH rear RDU HV header.

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering.
Remove leather over gloves and HV insulating gloves.
Release bolt securing LH rear HV harness from PRDU.

Note
1x bolt, 10mm, 6 Nm.
Position coolant drain container underneath LH rear of vehicle.
Release upper hose to LH PRDU heat exchanger.

Note
1x hose, Plug both ends.
Release lower hose to LH PRDU heat exchanger.

Note
1x hose, Plug both ends.
Remove coolant drain container from underneath vehicle.
Position oil drain container under the rear of vehicle.
Remove LH heat exchanger from PRDU.

Note
2x O-rings.

Install

Secure LH heat exchanger to PRDU.

Note
Lightly coat O-rings with clean KAF1 gearbox fluid, Do not pinch or deform O-ring during install, Ensure heat exchanger is fully seated, Do not allow coolant to enter PRDU oil passages, Prevent cross-contamination.
Install bolts securing PRDU heat exchanger.

Note
2x bolts, EP10, 5 Nm +30 degrees.
Remove oil drain container.
Secure lower hose to PRDU LH heat exchanger.

Note
1x hose clip, Perform push-pull-push test.
Secure upper hose to PRDU LH heat exchanger.

Note
1x hose clip, Perform push-pull-push test.
Install bolt securing LH rear HV harness from PRDU.

Note
1x bolt, 10mm, 6 Nm.
Secure LH RDU HV harness to battery pack.

Note
1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins.
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.
Connect First Responder Loop and LV battery connector.

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.
Release IP service panel.

Note
4x tabs, 2x datums.
Using laptop connect to vehicle with ethernet diag kit and Toolbox 3.

Note
Open Toolbox 3 website and establish connection to the vehicle. Media converter box is powered by laptop using USB, Ethernet connection will provide communication.
"Select ‘Actions’ tab and search for ‘PROC_DIREL_X_OIL-PUMP-DRAIN-CONTROL’".
"Select ‘Performance-Rear Drive Unit Oil Pump Drain Control’, click ‘Run’, and allow routine to complete.

Note
Select ‘X’ at top right of window to close once complete.
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.
Position oil drain container under RDU drain valve.
Remove bolts securing oil filter cover to RDU.

Note
2x bolts, EP10, 5 Nm + 20 degrees.
Remove oil filter assembly from RDU.

Note
Carefully insert plastic wedge between oil filter cover and RDU, in small increments work the wedge between oil filter cover until green O-ring is visible, remove oil filter by hand, residual oil will drain from housing, allow oil to drain.

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.
Remove fill plug from RDU.

Note
1x plug, 8mm Allen, 15 Nm.
Inspect seals and O-rings.

Note
1x O-ring, Inspect O-rings on removed, if damaged o-ring on plug replace affected plug.
Set up step ladder to access vehicle to run toolbox routine.
Re-establish vehicle connection to Toolbox 3.

Note
Open Toolbox 3 website and establish connection to the vehicle.
"Select ‘Actions’ tab and search for ‘PROC_DIREL_X_OIL-PUMP-DRAIN-CONTROL’".
"Select ‘Performance-Rear Drive Unit Oil Pump Drain Control’, click ‘Run’, and allow routine to complete.

Note
Select ‘X’ at top right of window to close once complete.
Drain the gearbox fluid from the rear drive unit.
Remove filter from oil filter cover.

Note
3x tabs, turn oil filter clockwise or counter-clockwise to release from oil filter cover.
Install filter onto oil filter cover.

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.

Note
3x tabs, turn oil filter clockwise or counter-clockwise to secure filter onto cover.
Install oil filter assembly into RDU.
Install bolts securing oil filter cover to RDU.

Note
2x bolts, EP10, 5 Nm + 20 degrees.
Set up fill kit with KAF1 gearbox fluid.

Note
Fill measuring container to 4 liters/4000 mL.
Install fluid transfer pump.

Note
Install fitting into fill plug port then insert transfer pump hose into fitting, Tub fitting is under development for service.
Set up fill process.

Note
Place measured fluid container in drain basket, fully submerge input hose, prime pump with fluid.
Select ‘Actions’ tab and search for ‘PROC_DIREL_X_OIL-PUMP-FILL-CONTROL.
Select ‘Performance-Rear Drive Unit Oil Pump Fill Control’, click ‘Run’, and allow routine to complete.

Note
Select ‘X’ at top right of window to close once complete.
Pump KAF1 gearbox fluid into the rear drive unit.
Remove transfer pump fitting from fill hole and Install fill plug into RDU.

Note
1x plug, 8mm Allen, 15 Nm, .
Spray area with brake cleaner and wipe residual fluid off with towel.
Remove oil drain container.
Apply Loctite 222 onto mid aeroshield bolts and install fasteners securing mid aeroshield to vehicle.

Note
16x bolts, 10mm, 6 Nm.
Install clips securing mid aeroshield.

Note
4x push clips.
Lower vehicle fully.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Remove coolant bottle cap.
Inspect coolant level and top off as necessary.

Note
Ensure that the fluid level is at the Max line, Top off fluid as required.
Select "Actions/Autodiag" tab and search for "Purge".
Select TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE, click "Run", and allow routine to complete.

Note
Make sure vehicle is not in drive state, Routine is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required.
Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit.
Inspect coolant level and top off as necessary.

Note
Ensure that the fluid level is at the Max line, Top off fluid as required.
Install coolant bottle cap.
Install IP service panel.

Note
2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP.
Install frunk assembly.

Note
8x bolts, 10mm, 5 Nm.
Install frunk carpet.

Note
Verify carpet is properly seated under the seal.
Install frunk access panel.

Note
3x clips, 3x hooks, 1x connector.
Install front underhood apron.

Note
12x clips, 3x datums.
Install LH underhood apron.

Note
11x clips, 2 datums.
Install RH underhood apron.

Note
11x clips, 2x datums.
Install rear underhood apron.

Note
11x clips, 2x datums.
Close hood.
Calibrate the rear doors.

Note
If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
Remove vehicle from lift.

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".

Model X Service Manual

Heat Exchanger - Rear Drive Unit - LH (Plaid) (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3