08/06/2022 11:58:44

Drive Unit - Front (1st Generation) (Remove and Install)

Correction Code 39012101

Special tools required for this procedure:

Supplier Part Number Description
Snap-on 1126496-00-B Wrench, Torque+Angle, 3/8 Dr
Bosch FMG-750 Transmission Jack 750 Kg Europe only
Tesla 1053350-00-A Transmission Jack Cradle Adapter Plate Europe only
Tesla 1063141-00-A 1/2 Ton Economy Transmission Jack North America, APAC only
Tesla 1048391-00-B Drive Unit Dual Motor Cradle - Delrin white
Tesla 1056566-00-A Locating Shim Set, Front Motor
Tesla 1126496-00-B Wrench, Torque+Angle, 3/8" Dr
Tesla 1139297-00-A SKT, 3/8" DR, Low Profile, 15mm
Tesla 1083189-**-A Tool, ATF oil refiller
Tesla 1498673-00-A KIT, CABLE AXLE REMOVER, MS/MX/M3
This procedure is for vehicles built through April 24, 2019. For vehicles built after April 24, 2019, see Drive Unit - Front (2nd Generation) (Remove and Install).

Removal

  1. Raise and support the vehicle on a 2 post lift.
  2. Recover the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue this procedure until the refrigerant recovery is complete.
  3. Remove the HEPA filter duct. See Duct - HEPA Filter (Remove and Replace) .
  4. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  5. Remove the center caps from the front wheels.
  6. Loosen the axle nuts.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not continue this procedure until the refrigerant recovery is complete.
  7. Remove the front wheels. See Wheel Assembly (Remove and Install).
  8. Remove the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
  9. Remove the HV Battery. See HV Battery (AWD) (Remove and Install) .
  10. Remove the 12V battery cage. See Cage - Battery - Auxiliary - 12V (Remove and Replace) .
  11. Remove the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 Nm). Do not remove the reservoir at this time.
  12. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.
  13. Clamp the coolant hose at the rear of the coolant reservoir.
  14. Carefully move the reservoir to the LH side of the vehicle and plug the coolant hole.
  15. Disconnect the compressor HV harness from the forward junction box.
  16. Remove the screw that attaches the ground strap to the compressor bracket (torque 8 Nm).
  17. Disconnect the low voltage harness from the compressor.
  18. Remove the nuts (x2) that attach the A/C lines to the compressor (torque 5.5 Nm).
  19. With the help of an assistant, remove the bolts (x3) that attach the A/C compressor bracket to the front drive unit (torque 10 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not spill any oil from the compressor. If oil spills from the compressor, the system might experience a failure due to inadequate lubrication after reinstallation.
  20. Remove the compressor and bracket from the vehicle as an assembly.
  21. Clamp the front drive unit coolant hoses on the front and LH side of the front drive unit, and then remove the coolant hoses from the front drive unit.
  22. Disconnect the ground strap from the left side of the body (torque 9 Nm).
  23. Disconnect the low voltage harness from the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    The connector has a 2-part locking system.

    To disconnect the connector:

    • 1. Pull the large red tab towards the rear of the connector.
    • 2. Push down on the small red tab.
  24. Lower the vehicle to access the wheelwell.
  25. Working from the LH wheelwell, remove powertrain coolant pump 2 from the bracket.
  26. Clamp the hoses that lead to powertrain coolant pump 2, and then disconnect the hoses.
  27. Move powertrain coolant pump 2 out of the way to gain access the LH side of the front drive unit.
  28. Remove the lower screws (x2) that attach the HV cables to the LH side of the front drive unit (torque 7 Nm).
  29. Remove the upper screws (x2) that attach the HV cables to the LH side of the front drive unit (torque 7 Nm), and then pull the HV cables away from the front drive unit.
  30. Remove the 1st generation front subframe assembly. See Subframe Assembly - Front - 1st Generation (Remove and Install) .
  31. Remove battery coolant pump 2 from the bracket on the chassis.
    Informational PurposesAn informational icon, calling your attention
    Note
    Battery coolant pump 2 is near the RH corner of the bulkhead.
  32. Clamp the coolant hose between battery coolant pump 2 and the chiller, and then remove the hose from the pump.
  33. Move the chiller and coolant pump to the RH side of the working area to provide clearance when removing the front drive unit.
  34. Remove the acoustic padding from the front drive unit.
  35. Drain the gearbox fluid from the front drive unit. See Gearbox Fluid - Front Drive Unit (1st Generation) (Drain and Refill) .
  36. Remove the RH axle nut.
  37. Remove the RH halfshaft from the jackshaft.
  38. Remove the RH halfshaft from the hub. Remove the RH halfshaft from the vehicle.
  39. Remove the bolts (x2) that attach the jackshaft to the front drive unit (torque 30 Nm).
  40. Remove the LH axle nut.
  41. Remove the LH halfshaft from the front drive unit.
  42. Remove the LH halfshaft from the hub. Remove the halfshaft from the vehicle.
  43. Remove the lower RH section of the acoustic cover from the front drive unit.
  44. Install the front drive unit cradle onto the transmission jack.
  45. Position the transmission jack underneath the front drive unit.
  46. Raise the transmission jack to support the weight of the front drive unit. Ensure that the ridge on the base of the front drive unit fits into the channel on the transmission jack.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Before continuing, make sure that the entire weight of the front drive unit is supported by the transmission jack.
  47. Remove the bolts (x2) that attach the LH front drive unit mount to the side rail (torque 65 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The LH front drive unit mount is removed with the front drive unit.
  48. Remove the bolts (x4) that attach the RH front drive unit mount and shear plate (if installed) to the front drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If a shear plate is installed, support the shear plate while removing the last two bolts. Once the last bolt is removed, the shear plate might rotate downward quickly and strike someone or a part of the vehicle. Once the last bolt is removed, there is nothing that supports the shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    The RH front drive unit mount remains in the vehicle as the front drive unit is removed.
  49. Lower the front drive unit out of the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that components are not caught on the front drive unit as it is being removed.

Installation

  1. Raise the front drive unit into the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that components are not caught on the front drive unit as it is being installed.
  2. If required, attach the shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Drive units with part number of 1035000-01-J or later do not require shear plates, and require 4 patchbolts (part number 1078944-00-B or later). Drive units with part number of 1035000-00-J or earlier require shear plates, and require 4 patchbolts (part number of 1050057-00-B or later).
    1. Insert and align the shear plate.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Install the shear plate on the TRA (torque reaction arm) facing the subframe, do not install the shear plate between the motor housing and the TRA
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Support the shear plate while you insert and finger-tighten the first two bolts. If only one bolt is inserted, the shear plate might rotate downward quickly and strike someone or a part of the vehicle.
    2. Install and finger-tighten the bolts (x4) that attach the shear plate and RH front drive unit mount to the front drive unit.
  3. Install and finger-tighten the bolts (x3) that attach the front drive unit to the LH mount.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Replace all patchbolt(s).
  4. Use the shim tools to make sure there is sufficient clearance between the RH front drive unit mount and the body.
    1. Position the shim tools as follows:
      1 2-pronged shim tool. Working from the underhood area, position the 2-pronged shim around the RH front drive unit mount front bushing.
      2 Hook shim tool. Reach beneath the front drive unit and position the hook shim tool between the mount and outer bushing.
      3 Straight shim tool. Reach downward between the V-brace and cross brace and position the straight shim tool between the mount and inner bushing.
      Informational PurposesAn informational icon, calling your attention
      Note
      Leave the shim tolls in place until prompted to remove, after all front drive unit mount bolts are fully torqued.
    2. Attach the 15 mm low profile socket to the torque + angle wrench.
    3. Set the torque + angle wrench to a torque value of 35 Nm.
  5. Torque the bolts.
    1. Torque the bolts (x4) to the RH front drive unit mount (torque 35 Nm) in the sequence shown:
    2. Set the torque + angle wrench to the correct angle value. For vehicles with a front drive unit with a part number of:
      • 1035000-01-J or later, set the torque angle to 55 degrees.

      • 1035000-00-J or earlier, set the torque angle to 75 degrees.
    3. Torque the bolts to the specified angle in the sequence shown:
    4. Torque the bolts (x3) that attach the front drive unit to the LH front drive unit mount (torque 38 Nm).
    5. Remove the shim tools, then attempt to reinstall them:
      • If all 3 shim tools can be easily installed and removed, the front drive unit is properly positioned.
      • If the shim tools can not be easily installed and removed, loosen all LH and RH front drive unit mount bolts and repeat step 4.a through step 5.e.
  6. Install the bolts (x2) that attach the LH front drive unit mount to the side rail (torque 65 Nm).
  7. Lower the transmission jack.
  8. Remove the transmission jack from underneath the vehicle.
  9. Remove the front drive unit cradle from the transmission jack.
  10. Install the lower RH acoustic cover onto the front drive unit.
  11. Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    When the drive unit was replaced by a new or remanufactured unit, before installing the LH halfshaft make sure to complete the checks on the LH output seal as described in the Installation section of Drive Unit - Front (1st Generation) (Remove and Replace).
    Install the LH halfshaft into the LH hub.
  12. Align the LH halfshaft so that the opening in the snap ring is down, facing towards the bottom of the front drive unit.
  13. Insert the LH halfshaft into the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not damage or displace the oil seal.
  14. Carefully push the LH halfshaft into the front drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
  15. Pull on the LH inner halfshaft cup to confirm that the LH halfshaft circlip is locked into place.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the halfshaft detaches from the front drive unit, repeat from step 12 and then test that the halftshaft is fully seated.
  16. Install the LH axle nut.
  17. Install the jackshaft to the front drive unit, and then install the bolts (x2) that attach the jackshaft to the front drive unit (torque 30 Nm).
  18. Install the RH halfshaft into the RH hub.
  19. Align the jackshaft so that the opening in the snap ring is down, facing towards the bottom of the front drive unit.
  20. Insert the RH halfshaft onto the jack shaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not damage or displace the oil seal.
  21. Carefully push the RH halfshaft onto the jack shaft until there is an audible "click" from the jackshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    There will be a slight pulling sensation on the halfshaft as the jackshaft circlip locks into place.
  22. Pull on the RH inner halfshaft cup to confirm that the jackshaft circlip is locked into place.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the halfshaft detaches from the jackshaft, repeat from step 19 and then test that the halftshaft is fully seated.
  23. Install the RH axle nut.
  24. Refill the drive unit with gearbox fluid. See Gearbox Fluid - Front Drive Unit (1st Generation) (Drain and Refill).
  25. Install the acoustic padding onto the front drive unit.
  26. Return the chiller and coolant pump from the RH side of the working area to near the front drive unit.
  27. Connect the coolant hose between the chiller and battery coolant pump 2, and then release the clamp from the hose.
  28. Install battery coolant pump 2 onto the bracket on the chassis.
  29. Install the front subframe assembly. See Subframe Assembly - Front - 1st Generation (Remove and Install) .
  30. Carefully inspect the connector seals of the HV cables. If any are damaged, replace them.
  31. Apply P-80 emulsion to the connector seals of the HV cables.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply P-80 emulsion to the HV terminals.
  32. Insert the HV cables into the LH side of the front drive unit, and then install the upper screws (x2) that attach the HV cables to the front drive unit (torque 7 Nm).
  33. Install the lower screws (x2) that attach the HV cables to the LH side of the front drive unit (torque 7 Nm).
  34. Return powertrain coolant pump 2 to the LH side of the front drive unit.
  35. Connect the coolant hoses to the powertrain coolant pump 2, and then release the clamp from the hoses.
  36. Install powertrain coolant pump 2 onto the bracket.
  37. Raise the vehicle to a working height.
  38. Connect the electrical harness to the front drive unit low voltage connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make the connection, then slide the red locking tab into the connector.
  39. Install the ground strap to the stud on the left side of the body, and then tighten the nut that attaches the ground strap to the body (torque 9 Nm).
  40. Connect the front drive unit coolant hoses to the front and LH side of the front drive unit, and then release the clamps from the hoses.
  41. With the help of an assistant, install the A/C compressor to the front drive unit, and then install the bolts (x3) that attach the A/C compressor bracket to the front drive unit (torque 10 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not spill any oil from the compressor. If oil spills from the compressor, the system might experience a failure due to inadequate lubrication after reinstallation.
  42. Insert the A/C lines into the compressor, and then install the nuts (x2) that attach the A/C lines to the compressor (torque 5.5 Nm).
  43. Connect the electrical harness to the compressor low voltage connector.
  44. Position the ground strap to the compressor bracket, and then install the screw that attaches the ground strap to the compressor bracket (torque 8 Nm).
  45. Connect the compressor HV harness to the forward junction box.
  46. Carefully return the coolant reservoir from the LH side of the vehicle, remove the plug from the coolant hole, and install the coolant hose at the rear of the coolant reservoir.
  47. Release the clamp from the coolant hose.
  48. Connect the electrical harness to the coolant reservoir coolant level sensor connector.
  49. Install the coolant reservoir to the front crossmember, and then install the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 Nm).
  50. Install the 12V battery cage. See Cage - Battery - Auxiliary - 12V (Remove and Replace) .
  51. Install the HV Battery. See HV Battery (AWD) (Remove and Install) .
  52. Install the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
  53. Install the front wheels. See Wheel Assembly (Remove and Install).
  54. Torque the axle nuts.
  55. Install the center caps onto the front wheels.
  56. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  57. Install the HEPA filter duct. See Duct - HEPA Filter (Remove and Replace) .
  58. Refill and bleed the cooling system. See Cooling System - Drain and Refill .
  59. Recharge the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .