04/06/2024 18:04:06

Fluid Coupling (Straight) - Front Drive Unit (Remove and Replace)

Correction code 39014202 4.68 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.

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. Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
  3. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  4. Position the 2 post lift pads for HV battery removal.
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  7. Remove the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  8. Remove the 2nd row mid floor panel. See:
  9. Remove the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  10. Remove the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  11. Remove the 2nd row rear floor panel. See:
  12. Remove the bolts (x2) that attach the busbar duct to the body, and then remove the busbar duct from the vehicle.
  13. Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  14. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  15. Remove the trunk side trim bracket. See:
  16. Disconnect LV power. See LV Power (Disconnect and Connect).
  17. 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.
  18. Remove the 3rd row seat cushion, if installed. See Cushion - Seat - 3rd Row (Remove and Replace).
  19. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  20. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  21. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  22. Remove the leather glove protectors and the HV insulating gloves.
  23. Remove the bolt that secures the charge port busbar connector access door.
  24. Remove the bolts (x2) that attach the charge port busbar connector to the DC input HV header.
    9 Nm (6.6 lbs-ft)
  25. Lift the charge port busbar connector to remove the connector from the DC input HV header.
  26. Remove the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  27. If the vehicle is equipped with a performance rear drive unit, slide the red connector locking tab, open the black release lever, and then disconnect the rear drive unit HV harness from the HV battery RH HV header.
  28. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  29. Remove the front skid plate. See Skidplate - Front (Remove and Replace).
  30. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  31. Remove the bolts (x3) that attach the LH cross brace to the LH casting, and then remove the cross brace from the vehicle.
  32. Move the coolant drain container to under the front drive unit.
  33. Release the clip, disconnect the front drive unit inverter inlet hose from the front drive unit inverter, and then immediately plug the fittings.
  34. Remove the bolt that attaches the front drive unit HV harness to the front drive unit, and then move the HV harness aside.
  35. Remove and discard the bolt that attaches the straight fluid coupling to the front drive unit inverter, and then remove the coupling from the inverter.

Install

  1. Wet the straight fluid coupling O-ring with coolant, install the fluid coupling into the front drive unit inverter, and then install a new bolt to attach the coupling to the inverter.
    6 Nm (4.4 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not install the fluid coupling with the O-ring dry.
  2. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    10 Nm (7.4 lbs-ft)
  3. 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.
  4. Move the coolant drain container out from underneath the vehicle.
  5. Install the LH cross brace to the LH casting, and then install the bolts (x3) that attach the cross brace to the casting.
    30 Nm (22.1 lbs-ft)
  6. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  7. Install the front skid plate. See Skidplate - Front (Remove and Replace).
  8. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  9. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery LH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  10. Install the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  11. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  12. Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.
  13. Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.
  14. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.
  15. Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.
    9 Nm (6.6 lbs-ft)
  16. Put on the HV insulating gloves and leather over gloves.
  17. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  18. Repeat step 42 for the other charge port busbar connector lead and DC input HV header bolt head.
  19. Remove the HV insulating gloves and leather over gloves.
  20. Install the bolt that secures the charge port busbar connector access door.
    9 Nm (6.6 lbs-ft)
  21. Install the LH inner reinforcement to the body, and then install the bolts (x10) that attach the reinforcement to the body.
    27 Nm (19.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bottom two bolts require improvising an 8 mm ratchet box-end wrench to turn the T40 socket.
  22. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  23. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  24. Connect LV power. See LV Power (Disconnect and Connect).
  25. Perform a cooling system air purge. See Cooling System (Partial Refill and Bleed).
  26. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  27. Install the trunk side trim bracket. See:
  28. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  29. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  30. Install the busbar duct to the body, and then install the bolts (x2) that attach the busbar duct to the body.
    2.5 Nm (1.8 lbs-ft)
  31. Install the 2nd row rear floor panel. See:
  32. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  33. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  34. Install the 2nd row mid floor panel. See:
  35. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  36. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  37. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  38. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  39. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.