2025-01-28
Heat Exchanger - Front Drive Unit (Remove & Replace)
Correction code
39308512
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 to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com.
NOTE: See to make sure wearing proper PPE when performing the below procedure.
- 2025-01-28: Revised procedure and added references.
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.
Note
This procedure requires the A/C
Refrigerant (Recovery and Recharge) procedure to be performed. If not already
automatically added to the Service Visit, add correction code 18200102 as a
separate activity to the Service Visit.
Removal
- Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Recover the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
- Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
- Remove the HEPA filter duct. See Duct - HEPA Filter (Remove and Replace).
- Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
- Remove the 12V battery bracket. See Cage - Battery - Auxiliary - 12V (Remove and Replace).
- Remove the wiper module. See Wiper Module (LHD) (Remove and Replace).
-
Remove coolant reservoir cap
Note1x cap
- Use vacuum suction tool to remove coolant from reservoir
-
Remove coolant reservoir cap
Note1x cap
-
Disconnect electrical connector for
coolant level sensor
Note1x connector
-
Remove coolant reservoir fasteners and
wire harness edge clip
Note4x bolts, 10mm, 6 Nm, 1x edge clip
-
Clamp and remove coolant hose and move
reservoir off to the side
Note1x coolant hose, Place absorbent material below hose to capture fluid
-
Release the ground connection at the
A/C compressor mount bracket
Note1x bolt, T25, 7 Nm
-
Disconnect the A/C compressor
harness
Note2x connectors, 2x fir clips
-
Remove discharge line from
compressor
Note1x nut, 10mm, 10 Nm, Discard O-rings after removal
- Move compressor harness away from bracket
-
Remove the fir tree clips securing the
A/C compressor HV harness to the front drive unit
Note2x fir tree clips
-
Disconnect A/C compressor harness at
FJB and release cable from drive unit
Note1x connector, 1x fir tree clip
-
Remove the fasteners securing the A/C
compressor to the FDU
Note3x bolts, E10, 10 Nm
-
Support the A/C compressor and remove
assembly from the front drive unit
NoteSet A/C compressor/bracket assembly to the side
-
Remove the upper fastener securing the
heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
-
Raise vehicle fully and lower onto
locks
NoteSet 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 front aero shield
Note6x bolts, 10mm, 3 Nm, 14x clips
-
Remove front bash plate
extrusion
Note2x bolts, T30, 16 Nm
-
Loosen 21mm bolts securing front of HV
battery
Note2x bolts, 21mm, 115 Nm, Discard after removal
-
Remove 21mm bolts securing front of HV
battery
Note2x bolts, 21mm, 115 Nm, Discard after removal
-
Loosen front four HV battery
bolts
Note4x patch bolts, 13mm, 30 Nm, Discard after removal
-
Remove front four HV battery
bolts
Note4x patch bolts, 13mm, 30 Nm, Discard after removal
-
Remove skid plate from front
subframe
Note2x bolts, 10mm, 9 Nm
- Position the oil drain under oil pump area
-
Disconnect the front drive unit oil
pump connector
Note1x electrical connector
-
Remove the fasteners securing the oil
pump to the FDU
Note2x bolts, EP10, 5 Nm + 20 degrees
-
Remove the oil pump from the FDU
NotePry the pump away from the FDU with a pry tool or flat blade screwdriver, Ensure the FDU casting is not damaged, Allow the oil to drain from the FDU
- Position fold able funnel
-
Remove the oil filter from the
FDU
NoteSpin counterclockwise, 3 Nm and 135 degrees, Allow oil to drain,Install a new oil filter after removal
- Remove foldable funnel
- Remove oil drain container from under vehicle
- Position coolant drain container under the LH front corner of the vehicle to catch vehicle coolant
-
Release FDU outlet hose from heat
exchanger and plug heat exchanger
Note1x spring clip, Allow excess coolant to fully drain
-
Release upper coolant hose from heat
exchanger and plug heat exchanger
Note1x spring clip, Allow excess coolant to fully drain
-
Release the clip securing the oil pump
harness to the heat exchanger
Note1x fir tree clip
-
Remove the fir tree clip from the heat
exchanger and move hose aside
Note1x fir tree clip
-
Remove the lower fastener securing the
heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
-
Remove heat exchanger from FDU
assembly
NoteSome oil will spill out of the FDU after removal
Installation
-
Inspect seals of new heat
exchanger
NoteReplace any damaged seals, Lubricate with drive unit oil before installation
- Position heat exchanger onto FDU assembly
-
Install the upper fastener securing
the heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
-
Install the lower fastener securing
the heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
-
Install the clip securing the upper
coolant hose to the heat exchanger
Note1x fir tree clip
-
Secure upper coolant hose onto heat
exchanger
Note1x spring clip, Perform push-pull-push test
-
Secure FDU outlet hose onto heat
exchanger
Note1x spring clip, Perform push-pull-push test
-
Install the clip securing the oil pump
harness pigtail to the heat exchanger
Note1x fir tree clip
- Remove coolant drain container from under the LH front of the vehicle
- Position the oil drain under oil pump area
-
Remove the fill plug from the
FDU
Note1x plug, 8mm Allen, 15 Nm
-
Inspect seals and o-rings
NoteInspect 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
-
Install new oil filter
NoteSpin clockwise, 3 Nm and 135 degrees, Lubricate seal prior to installation
-
Install the oil pump into the
FDU
NoteUse residual oil in the oil pump cavity to lubricate the seals of the oil pump before installation, Align bolt holes with housing
-
Install the fasteners securing the oil
pump to the FDU
Note2x bolts, EP10, 5 Nm + 20 degrees
-
Set up fill kit
NoteSet fluid level to 2000 mL in measuring container
-
Install fluid transfer pump
NoteTrim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm
-
Set up fill process
NotePlace measured fluid container in drain basket, fully submerge input hose, prime pump with ATF fluid
-
Connect the 12V power supply to oil
pump
Note1x connector
-
Pump ATF fluid into Raven front drive
unit
NoteAssistant 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
-
Install fill plug into the FDU
Note1x plug, 8mm Allen, 15 Nm
-
Disconnect 12V power supply tool from
oil pump
Note1x electrical connector
-
Connect the front drive unit oil pump
connector
Note1x electrical connector
- Spray area with brake cleaner and wipe residual fluid off with towel
- Remove oil drain from under vehicle
- Install skid plate between battery pack and subframe
-
Install bolts that secure skid plate
to subframe
Note2x bolts, 10mm, 10 Nm
-
Install front bolts for HV battery
with battery powered drill
Note4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
-
Torque the front bolts for HV
battery
Note4x bolts, 13mm, 30 Nm
-
Install 21mm bolts at front of HV
battery with battery powered drill
Note2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step
-
Torque bolts securing front of HV
battery to vehicle
Note2x bolts, 21mm, 115 Nm
-
Install front bash plate
extrusion
Note2x bolts, T30, 16 Nm
-
Install front aero shield
Note6x bolts, 10mm, 3 Nm, 14x clips
- Lower vehicle fully
-
Close small access door
Note2x tabs
-
Install charger access panel
Note11x patch bolts, T20, 2 Nm, Install new patch bolts
-
Clean area around charger access panel
prior to installation of new warranty label
NoteAllow IPA to dry for at least 1 minute
-
Install new warranty label
NoteClean area with IPA alcohol wipes and allow area to dry before placing new warranty label
-
Install A/C compressor
Note3x bolts, E10, 10 Nm
-
Install discharge A/C line to
compressor
Note1x nuts, 10mm, 10 Nm, Replace the O-rings
-
Connect the A/C compressor
harness
Note2x electrical connectors, 2x fir clips
-
Secure the ground connection at the
A/C compressor mount bracket
Note1x bolt, T25, 7 Nm
-
Install the fir tree clips securing
the A/C compressor HV harness to the front drive unit
Note2x fir tree clips
-
Connect A/C compressor harness to FJB
Note1x connector
-
Connect coolant hose to reservoir and
remove hose clamp
Note1x coolant hose
-
Connect coolant reservoir level sensor
Note1x connector
-
Install fasteners securing coolant
reservoir to shock tower cross member
Note4x bolts, 10mm, 6 Nm
-
Install HEPA filter duct
Note1x clip
- Install the wiper module. See Wiper Module (LHD) (Remove and Replace).
- Install the 12V battery bracket. See Cage - Battery - Auxiliary - 12V (Remove and Replace).
- Reconnect 12V power. See Disconnect 12V Power.
- Reinstall all components that were removed during the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Install the HEPA filter duct. See Duct - HEPA Filter (Remove and Replace).
- Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
- Recharge the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Calibrate the falcon doors using the MCU.