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 ServiceManualFeedback@tesla.com. NOTE: See to make sure wearing proper PPE when performing the below procedure.

  • 2025-01-28: Revised procedure and added references.
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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.
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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

  1. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  2. Recover the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  3. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  4. Remove the HEPA filter duct. See Duct - HEPA Filter (Remove and Replace).
  5. Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
  6. Remove the 12V battery bracket. See Cage - Battery - Auxiliary - 12V (Remove and Replace).
  7. Remove the wiper module. See Wiper Module (LHD) (Remove and Replace).
  8. Remove coolant reservoir cap
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    Note
    1x cap
  9. Use vacuum suction tool to remove coolant from reservoir
  10. Remove coolant reservoir cap
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    Note
    1x cap
  11. Disconnect electrical connector for coolant level sensor
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    Note
    1x connector
  12. Remove coolant reservoir fasteners and wire harness edge clip
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    Note
    4x bolts, 10mm, 6 Nm, 1x edge clip
  13. Clamp and remove coolant hose and move reservoir off to the side
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    Note
    1x coolant hose, Place absorbent material below hose to capture fluid
  14. Release the ground connection at the A/C compressor mount bracket
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    Note
    1x bolt, T25, 7 Nm
  15. Disconnect the A/C compressor harness
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    Note
    2x connectors, 2x fir clips
  16. Remove discharge line from compressor
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    1x nut, 10mm, 10 Nm, Discard O-rings after removal
  17. Move compressor harness away from bracket
  18. Remove the fir tree clips securing the A/C compressor HV harness to the front drive unit
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    Note
    2x fir tree clips
  19. Disconnect A/C compressor harness at FJB and release cable from drive unit
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    Note
    1x connector, 1x fir tree clip
  20. Remove the fasteners securing the A/C compressor to the FDU
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    Note
    3x bolts, E10, 10 Nm
  21. Support the A/C compressor and remove assembly from the front drive unit
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    Note
    Set A/C compressor/bracket assembly to the side
  22. Remove the upper fastener securing the heat exchanger to the FDU
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    Note
    1x bolt, EP10, 5 Nm + 30 degrees
  23. Raise vehicle fully and lower onto locks
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    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
  24. Remove front aero shield
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    Note
    6x bolts, 10mm, 3 Nm, 14x clips
  25. Remove front bash plate extrusion
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    2x bolts, T30, 16 Nm
  26. Loosen 21mm bolts securing front of HV battery
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    2x bolts, 21mm, 115 Nm, Discard after removal
  27. Remove 21mm bolts securing front of HV battery
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    2x bolts, 21mm, 115 Nm, Discard after removal
  28. Loosen front four HV battery bolts
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    4x patch bolts, 13mm, 30 Nm, Discard after removal
  29. Remove front four HV battery bolts
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    4x patch bolts, 13mm, 30 Nm, Discard after removal
  30. Remove skid plate from front subframe
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    2x bolts, 10mm, 9 Nm
  31. Position the oil drain under oil pump area
  32. Disconnect the front drive unit oil pump connector
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    Note
    1x electrical connector
  33. Remove the fasteners securing the oil pump to the FDU
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    Note
    2x bolts, EP10, 5 Nm + 20 degrees
  34. Remove the oil pump from the FDU
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    Pry 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
  35. Position fold able funnel
  36. Remove the oil filter from the FDU
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    Spin counterclockwise, 3 Nm and 135 degrees, Allow oil to drain,Install a new oil filter after removal
  37. Remove foldable funnel
  38. Remove oil drain container from under vehicle
  39. Position coolant drain container under the LH front corner of the vehicle to catch vehicle coolant
  40. Release FDU outlet hose from heat exchanger and plug heat exchanger
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    1x spring clip, Allow excess coolant to fully drain
  41. Release upper coolant hose from heat exchanger and plug heat exchanger
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    1x spring clip, Allow excess coolant to fully drain
  42. Release the clip securing the oil pump harness to the heat exchanger
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    Note
    1x fir tree clip
  43. Remove the fir tree clip from the heat exchanger and move hose aside
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    1x fir tree clip
  44. Remove the lower fastener securing the heat exchanger to the FDU
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    Note
    1x bolt, EP10, 5 Nm + 30 degrees
  45. Remove heat exchanger from FDU assembly
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    Note
    Some oil will spill out of the FDU after removal

Installation

  1. Inspect seals of new heat exchanger
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    Replace any damaged seals, Lubricate with drive unit oil before installation
  2. Position heat exchanger onto FDU assembly
  3. Install the upper fastener securing the heat exchanger to the FDU
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    Note
    1x bolt, EP10, 5 Nm + 30 degrees
  4. Install the lower fastener securing the heat exchanger to the FDU
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    Note
    1x bolt, EP10, 5 Nm + 30 degrees
  5. Install the clip securing the upper coolant hose to the heat exchanger
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    Note
    1x fir tree clip
  6. Secure upper coolant hose onto heat exchanger
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    1x spring clip, Perform push-pull-push test
  7. Secure FDU outlet hose onto heat exchanger
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    1x spring clip, Perform push-pull-push test
  8. Install the clip securing the oil pump harness pigtail to the heat exchanger
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    Note
    1x fir tree clip
  9. Remove coolant drain container from under the LH front of the vehicle
  10. Position the oil drain under oil pump area
  11. Remove the fill plug from the FDU
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    Note
    1x plug, 8mm Allen, 15 Nm
  12. Inspect seals and o-rings
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    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
  13. Install new oil filter
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    Spin clockwise, 3 Nm and 135 degrees, Lubricate seal prior to installation
  14. Install the oil pump into the 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
  15. Install the fasteners securing the oil pump to the FDU
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    Note
    2x bolts, EP10, 5 Nm + 20 degrees
  16. Set up fill kit
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    Set fluid level to 2000 mL in measuring container
  17. Install fluid transfer pump
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    Trim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm
  18. Set up fill process
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    Place measured fluid container in drain basket, fully submerge input hose, prime pump with ATF fluid
  19. Connect the 12V power supply to oil pump
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    1x connector
  20. Pump ATF fluid into Raven front drive unit
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    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
  21. Install fill plug into the FDU
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    Note
    1x plug, 8mm Allen, 15 Nm
  22. Disconnect 12V power supply tool from oil pump
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    Note
    1x electrical connector
  23. Connect the front drive unit oil pump connector
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    1x electrical connector
  24. Spray area with brake cleaner and wipe residual fluid off with towel
  25. Remove oil drain from under vehicle
  26. Install skid plate between battery pack and subframe
  27. Install bolts that secure skid plate to subframe
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    Note
    2x bolts, 10mm, 10 Nm
  28. Install front bolts for HV battery with battery powered drill
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    Note
    4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
  29. Torque the front bolts for HV battery
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    Note
    4x bolts, 13mm, 30 Nm
  30. Install 21mm bolts at front of HV battery with battery powered drill
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    Note
    2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step
  31. Torque bolts securing front of HV battery to vehicle
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    Note
    2x bolts, 21mm, 115 Nm
  32. Install front bash plate extrusion
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    Note
    2x bolts, T30, 16 Nm
  33. Install front aero shield
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    Note
    6x bolts, 10mm, 3 Nm, 14x clips
  34. Lower vehicle fully
  35. Close small access door
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    Note
    2x tabs
  36. Install charger access panel
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    Note
    11x patch bolts, T20, 2 Nm, Install new patch bolts
  37. Clean area around charger access panel prior to installation of new warranty label
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    Note
    Allow IPA to dry for at least 1 minute
  38. Install new warranty label
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    Note
    Clean area with IPA alcohol wipes and allow area to dry before placing new warranty label
  39. Install A/C compressor
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    Note
    3x bolts, E10, 10 Nm
  40. Install discharge A/C line to compressor
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    Note
    1x nuts, 10mm, 10 Nm, Replace the O-rings
  41. Connect the A/C compressor harness
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    Note
    2x electrical connectors, 2x fir clips
  42. Secure the ground connection at the A/C compressor mount bracket
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    Note
    1x bolt, T25, 7 Nm
  43. Install the fir tree clips securing the A/C compressor HV harness to the front drive unit
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    Note
    2x fir tree clips
  44. Connect A/C compressor harness to FJB
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    Note
    1x connector
  45. Connect coolant hose to reservoir and remove hose clamp
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    Note
    1x coolant hose
  46. Connect coolant reservoir level sensor
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    Note
    1x connector
  47. Install fasteners securing coolant reservoir to shock tower cross member
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    Note
    4x bolts, 10mm, 6 Nm
  48. Install HEPA filter duct
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    Note
    1x clip
  49. Install the wiper module. See Wiper Module (LHD) (Remove and Replace).
  50. Install the 12V battery bracket. See Cage - Battery - Auxiliary - 12V (Remove and Replace).
  51. Reconnect 12V power. See Disconnect 12V Power.
  52. Reinstall all components that were removed during the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  53. Install the HEPA filter duct. See Duct - HEPA Filter (Remove and Replace).
  54. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  55. Recharge the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  56. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  57. Calibrate the falcon doors using the MCU.