2026-11-12

Drive Unit - Rear - Large (Remove and Replace)

Correction Code 40010702

  • 2023-12-01: All new procedure with coolant manifold considerations.
  • 2023-07-21: Added Note about security-related toolbox actions.
Note
Some of the Toolbox Actions within this procedure are related to vehicle security and can only be performed by Tesla employees or third parties authorized to perform security-related Toolbox Actions. To learn more, see the Service Subscription FAQs available in the user account dropdown menu.
Note
Loosen suspension fasteners by hand, then use a cordless electric drill with a 3/8 in drive adapter and an 3/8 in drive air ratchet wrench.
Note
This procedure includes the removal of the new drive unit from the shipping crate, unloading the new drive unit on the powertrain table, and boxing up the old drive unit on the crate.

Removal

  1. Check the part number of the replacement large drive unit. If it is in this table, the drive unit might need to be reworked with an updated coolant manifold.
    1002633-00-F 1002633-00-M 1002633-00-T 1002633-01-R 1025276-00-Q 1025598-00-Q
    1002633-00-H 1002633-00-Q 1002633-01-C 1002633-01-T 1025598-00-P 1025598-00-T
    Note
    The rework will occur much later in the procedure.
  2. Verify there is no abnormal tire wear per Courtesy Inspection.
  3. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  4. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  5. Remove the HEPA filter. See Filter - HEPA (Remove and Replace).
  6. Disconnect 12V power. See Disconnect 12V Power.
  7. Set multimeter to DC voltage, and verify that the multimeter is properly measuring voltage at the 12V battery.
  8. Remove the lug nut covers (x5) from the LH rear wheel.
  9. Loosen the lug nuts (x5) on the LH rear wheel.
  10. Remove the lug nut covers (x5) from the RH rear wheel.
  11. Loosen the lug nuts (x5) on the RH rear wheel.
  12. Raise the vehicle, remove the lug nuts (x5), and then remove the RH rear wheel.
  13. Remove the lug nuts (x5), and then remove the LH rear wheel.
  14. Release the locking tab, and then disconnect the electrical harness from the LH rear parking brake caliper connector.
  15. Remove the nut that attaches the LH rear air spring module to the LH rear knuckle.
    Note
    Do not remove the bolt. It will be removed in a later step.
  16. Remove the bolts (x2) that attach the LH rear brake calipler to the LH rear knuckle, and then hang the caliper from the body with an S hook.
  17. Release the locking tab, and then disconnect the electrical harness from the RH rear parking brake caliper connector.
  18. Remove the nut that attaches the RH rear air spring module to the RH rear knuckle.
    Note
    Do not remove the bolt. It will be removed in a later step.
  19. Remove the bolts (x2) that attach the RH rear brake calipler to the RH rear knuckle, and then hang the caliper from the body with an S hook.
  20. Remove the clips (x2) that attach the RH shear plate to the RH wheel arch liner.
  21. Remove the T25 screws (x3), the 10mm bolt, and discard the 15mm nut that attach the RH shear plate to the body and HV battery.
  22. Remove the clips (x2) that attach the LH shear plate to the LH wheel arch liner.
    Note
    2x push clips.
  23. Remove the T25 screws (x3), the 10mm bolt, and discard the 15mm nut that attach the LH shear plate to the body and HV battery.
  24. Remove the LH and RH clips that attach the mid aero shield to the body.
  25. Remove the bolts (x20) that attach the mid aero shield to the body, and then remove the mid aero shield from the body.
  26. Remove the nuts (x3) that attach the LH mid aero shield reinforcement to the body, and then remove the reinforcement from the body.
  27. Remove the nuts (x3) and the clip that attach the RH mid aero shield reinforcement to the body, and then remove the reinforcement from the body.
  28. Remove the bolts (x2) that attach the rear skid plate to the rear subframe, and then remove the skid plate from the subframe.
  29. Disconnect the electrical harness from the large drive unit low voltage connector.
  30. Fully loosen the bolt, and then remove the HV cable cover from the large rear drive unit.
  31. Remove and discard the O-rings (x2) from the HV cable cover.
  32. Remove all items from pockets and ensure not wearing metal items.
  33. Inspect the HV insulating gloves for damage and leaks.
    Note
    Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  34. Put on the HV insulating gloves and leather over gloves.
    Note
    Make sure to wear proper PPE.
  35. Verify no High Voltage is present in the HV harness and large drive unit.
    Note
    Measure B+ to B-, B+ to ground, and B- to ground. If voltage is greater than 10V, pack contactors are not open or welded. Stop work and reach out to Service Engineering.
  36. Remove leather over gloves and HV insulating gloves.
  37. Remove and discard the bolts (x2) that attach the HV harness to the large drive unit.
    Note
    Do not remove the HV harness at this time.
  38. Remove the cable ties (x2) that attach the HV harness and subframe harness to the rear subframe.
  39. Release the clip, and then disconnect the rear subframe harness from the main body harness connectors (x3).
  40. Position a coolant drain collector under the RH rear side of the vehicle.
  41. Clamp the large drive unit powertrain outlet hose, move the spring clamp, remove the hose from the large drive unit, and immediately cap the large drive unit outlet.
  42. Release the clips (x3) that attach the powertrain outlet hose to the rear subframe.
  43. Position the coolant drain collector under the LH rear side of the vehicle.
  44. Clamp the large drive unit powertrain inlet hose, move the spring clamp, remove the hose from the large drive unit, and immediately cap the large drive unit inlet.
  45. Move the coolant drain collector out from under the vehicle.
  46. Position the oil drain collector under the large drive unit drain plug.
  47. Remove the large drive unit drain plug from the large drive unit, and allow the fluid to drain.
  48. Lubricate the drain plug O-ring with fluid, and then instal the drain plug into the large drive unit.
    28 Nm (20.6 lbs-ft)
    CAUTION
    Do not over-torque as it will crack the large drive unit case.
  49. Move the oil drain collector out from under the vehicle, and clean any residual fluid from the large drive unit and rear subframe.
  50. Mark the locations of the LH and RH front rear subframe bolts for easier installation.
  51. Position the powertrain lift table under the rear subframe.
  52. Supply shop air to the powertrain table.
  53. Raise the powertrain lift to the rear subframe, align the subframe fixture dowels to the holes in the front of the rear subframe, and then raise the lift more to support the weight of the rear subframe.
    Note
    Lower the vehicle if the powertrain lift cannot reach the rear subframe.
  54. Remove the bolts (x4) that attach the rear subframe to the body.
  55. With the help of an assistant, carefully lower the powertrain lift approximately 3 in (75 mm) to gain access to the remaining attachments.
    Note
    Make sure no hoses or harnesses are caught while lowering, and that the HV battery tabs are not bent or damaged.
  56. Remove and discard the bolt that attaches the ground strap to the RH side of the larger drive unit, and remove the ground strap from the unit.
  57. Remove the bolt that attaches the HV harness bracket to the large drive unit, and then remove the bracket from the drive unit.
  58. Remove the bolt that attaches the LH rear air spring module to the LH rear knuckle.
    Note
    Adjust powertrain lift height to relieve loading on bolt.
  59. Remove the bolt that attaches the RH rear air spring module to the RH rear knuckle.
    Note
    Adjust powertrain lift height to relieve loading on bolt.
  60. With the help of an assistant, remove the HV harness from the large drive unit while lowering the powertrain lift.
    Note
    Make sure hoses and harnesses are not caught while lowering.
  61. Move the rear subframe out from under the vehicle.
  62. Remove the O-rings (x2) from the large drive unit HV harness.
    Note
    Inspect the condition of the HV harness and replace if corroded.
  63. Release the clip that attaches the LH rear parking brake harness to the LH toe link.
  64. Release the clip that attaches the RH rear parking brake harness to the RH toe link.
  65. Disconnect the rear subframe harness from the large drive unit encoder sensor connector.
  66. Release the LH rear wheel speed sensor grommet from the LH rear knuckle.
  67. Release the RH rear wheel speed sensor grommet from the RH rear knuckle.
  68. Remove the LH rear stabilizer bar bushing bolt.
  69. Remove the RH rear stabilizer bar bushing bolt.
  70. Remove the nut and bolt that attach the LH rear toe link to the LH rear knuckle.
  71. Remove the bolt that attaches the LH rear upper link to the LH rear knuckle.
  72. Separate the LH rear axle from the large drive unit.
    Note
    Use a cable tie to hold the axle removal tool in place.
  73. Remove the nut and bolt that attach the RH rear toe link to the RH rear knuckle.
  74. Remove the bolt that attaches the LH rear upper link to the LH rear knuckle.
  75. Separate the RH rear axle from the large drive unit.
    Note
    Use a cable tie to hold the axle removal tool in place.
  76. Attach the large drive unit sling tool hooks (x3) to the large drive unit at the front, side and rear mounting points, and hand tighten the bolts (x3) within the hooks.
  77. Position the powertrain lift under the gantry.
  78. Attach the large drive unit sling tool to the gantry.
  79. Raise the large drive unit sling tool so that there is slight tension in the cables.
  80. Remove and discard the bolts (x3) that attach the large drive unit to the side drive unit mount.
  81. Remove the nuts (x2) and bolts (x2) that attach the large drive unit front and rear bushings to the rear subframe.
    Note
    Adjust tension in large drive unit sling tool cables as needed to remove loading on the bolts.
  82. Raise the large drive unit sling tool and lift the large drive unit out of the rear subframe.
    Note
    Make sure not to damage the large drive unit speed sensor or the inlet manifold fitting while lifting.
  83. Remove the bolt that attaches the large drive unit coolant manifold inlet fitting to the large drive unit coolant manifold, and then remove the inlet fitting from the coolant manifold.
    Note
    Gently twisting and rocking the fitting will help free it from the manifold.
  84. Position an empty drive unit crate or pallet under the large drive unit..
  85. Lower the large drive unit into the drive unit crate or onto the pallet.
    Note
    MRB the drive unit.

Installation

  1. Check the part number of the replacement large drive unit. If it is in this table, the drive unit might need to be reworked with an updated coolant manifold.
    1002633-00-F 1002633-00-M 1002633-00-T 1002633-01-R 1025276-00-Q 1025598-00-Q
    1002633-00-H 1002633-00-Q 1002633-01-C 1002633-01-T 1025598-00-P 1025598-00-T
    Note
    The rework will occur later in the procedure.
  2. Transfer the large drive unit sling tool hooks (x3) to the replacement large drive unit at the front, side and rear mounting points, and hand tighten the bolts (x3) within the hooks.
  3. Position the gantry over the replacement large drive unit.
  4. Attach the large drive unit sling tool to the gantry.
  5. Raise the replacement large drive unit out of the large drive unit crate.
  6. Inspect the replacement large drive unit for a part number on the coolant manifold.
    • If there is a part number on the coolant manifold, no rework is necessary, go to step 7.
    • If no part number is seen, the coolant manifold must be reworked. Perform SB-23-40-00x now as a separate activity in the Service Visit. After reworking the coolant manifold, return to this procedure, step 8.
  7. Install the large drive unit coolant manifold inlet fitting into the replacement large drive unit coolant manifold, and then install the bolt that attaches the inlet fitting to the coolant manifold.
    7.2 Nm (5.3 lbs-ft)
    Note
    Gently twisting and rocking the fitting will help insert it into the manifold.
  8. Move the powertrain lift and rear subframe to under the gantry.
  9. Lower the large drive unit sling tool and set the replacement large drive unit into the rear subframe.
    Note
    Make sure not to damage the large drive unit speed sensor or the inlet manifold fitting while lowering.
  10. Install the nuts (x2) and bolts (x2) that attach the large drive unit front and rear bushings to the rear subframe.
    Note
    Adjust tension in large drive unit sling tool cables as needed to ease installation of the bolts.
  11. Install new bolts (x3) to attach the large drive unit to the side drive unit mount.
  12. Release tension in the large drive unit sling tool, and then remove the sling tool from the gantry.
  13. Make sure that the gap in the snap ring at the end of the RH rear axle is down, carefully install the RH rear axle into the large drive unit making sure not to damage the oil seal, and then verify the axle is fully seated.
  14. Install and hand-tighten the bolt that attaches the RH rear upper link to the RH rear knuckle.
    Note
    Bolt will be torqued in a later step.
  15. Install and hand-tighten the bolt and new nut to attach the RH rear toe link to the RH rear knuckle.
    Note
    Fasteners will be torqued in a later step.
  16. Fasten the RH rear wheel speed sensor grommet to the RH rear knuckle.
  17. Fill the large drive unit with 1,400 ml of SK lubricant 212-B through the open axle oil seal.
  18. Make sure that the gap in the snap ring at the end of the LH rear axle is down, carefully install the LH rear axle into the large drive unit making sure not to damage the oil seal, and then verify the axle is fully seated.
  19. Install and hand-tighten the bolt that attaches the LH rear upper link to the LH rear knuckle.
    Note
    bolt will be torqued in a later step.
  20. Install and hand-tighten the bolt and new nut to attach the LH rear toe link to the LH rear knuckle.
    Note
    Fasteners will be torqued in a later step.
  21. Fasten the LH rear wheel speed sensor grommet to the LH rear knuckle.
  22. Install the LH rear stabilizer bar bushing bolt.
  23. Install the RH rear stabilizer bar bushing bolt.
  24. Fasten the clip that attaches the RH rear parking brake harness to the RH toe link.
  25. Fasten the clip that attaches the LH rear parking brake harness to the LH toe link.
  26. Connect the rear subframe harness to the large drive unit encoder sensor connector.
  27. Replace the cable ties that will secure the HV harness and subframe harness to the rear subframe later in the procedure.
    Note
    Do not secure the cable ties at this time.
  28. Install new O-rings (x2) onto the large drive unit HV harness and apply silicone lubricant.
  29. Move the powertrain lift and rear subframe to under the rear of the vehicle, and then align to where it will install.
  30. Supply shop air to the powertrain table.
  31. With the help of an assistant, carefully raise the powertrain lift until the rear subframe is approximately 3 in (75 mm) from the body, and then install the HV harness into to the large drive unit.
    Note
    Make sure hoses and harnesses are not caught while raising.
  32. Install the HV harness bracket to the large drive unit, and then install the bolt that attaches the bracket to the drive unit.
  33. Install the ground strap to the RH side of the larger drive unit, and install a new bolt that attaches the ground strap to the unit.
  34. Install the bolt that attaches the RH rear air spring module to the RH rear knuckle.
    Note
    Adjust powertrain lift height to ease installation of the bolt.
  35. Install the bolt that attaches the LH rear air spring module to the LH rear knuckle.
    Note
    Adjust powertrain lift height to ease installation of the bolt.
  36. With the help of an assistant, carefully raise the powertrain lift so that the rear subframe is up against the body.
    Note
    Make sure no hoses or harnesses are caught while raising, and that the HV battery tabs are not bent or damaged.
  37. Install and hand-tighten the bolts (x4) that attach the rear subframe to the body.
    Note
    Thread the bolts for at least 5 turns or until they are bottomed as they will support the weight of the subframe.
  38. Use a prybar to nudge the rear subframe so that the marks at the LH and RH front rear subframe bolts are centered.
  39. Tighten the bolts (x4) that attach the rear subframe to the body.
  40. Lower the powertrain lift.
  41. Disconnect shop air from the powertrain lift, and then move the lift out from under the vehicle.
  42. Position the coolant drain collector under the LH rear side of the vehicle.
  43. Remove the cap from the large drive unit inlet fitting, immediately install the large drive unit powertrain inlet hose to the manifold inlet fitting, move the spring clamp, and then remove the hose clamp.
  44. Position the coolant drain collector under the RH rear side of the vehicle.
  45. Fasten the clips (x3) that attach the powertrain outlet hose to the rear subframe.
  46. Remove the cap from the large drive unit outlet, immediately install the large drive unit powertrain outlet hose to the large drive unit outlet, move the spring clamp, and then remove the hose clamp.
  47. Move the coolant drain collector out from under the vehicle.
  48. Connect the rear subframe harness to the main body harness connectors (x3), and then fasten the clip.
  49. Secure cable ties (x2) to attach the HV harness and subframe harness to the rear subframe.
  50. Install new bolts (x2) to attach the HV harness to the large drive unit.
  51. Install new O-rings (x2) onto the HV cable cover.
  52. Install the HV cable cover to the large rear drive unit, and then tighten the bolt that attaches the cover to the drive unit.
  53. Connect the electrical harness to the large drive unit low voltage connector.
  54. Install the rear skid plate to the rear subframe, and then install the bolts (x2) that attach the skid plate to the subframe.
  55. Install the LH rear brake calipler to the LH rear knuckle, and then install the bolts (x2) that attach the caliper to the knuckle.
    CAUTION
    Make sure the brake caliper and hoses are not twisted when hanging the caliper or during reinstallation, as this can damage the brake hose.
  56. Install and hand-tighten the nut that attaches the LH rear air spring module to the LH rear knuckle.
    Note
    Fasteners will be torqued in a later step.
  57. Connect the electrical harness to the LH rear parking brake caliper connector, and then fasten the locking tab.
  58. Install the hub jack adapter onto the LH rear hub, and then installl and hand-tighten the lug nuts that attach the jack adapter to the hub.
  59. Position a support stand under the hub jack adapter and raise the LH rear suspension to approximate ride height.
  60. Adjust the support stand to set the distance from the LH upper fore link to the bolt on the frame rail to 85mm +/-5mm.
  61. Tighten the nut and bolt that attach the LH air spring module to the LH rear knuckle.
  62. Tighten the bolt that attaches the LH upper link to the LH rear knuckle.
  63. Tighten the nut and bolt that attach the LH toe link to the LH rear knuckle.
  64. Remove the support stand from the hub jack adapter.
  65. Remove the lug nuts (x5) that attach the hub jack adapter onto the LH rear hub, and then remove the jack adapter from the hub.
  66. Install the LH rear wheel, and then install the lug nuts (x5).
  67. Install the RH rear brake calipler to the RH rear knuckle, and then install the bolts (x2) that attach the caliper to the knuckle.
    CAUTION
    Make sure the brake caliper and hoses are not twisted when hanging the caliper or during reinstallation, as this can damage the brake hose.
  68. Install and hand-tighten the nut that attaches the RH rear air spring module to the RH rear knuckle.
    Note
    Fasteners will be torqued in a later step.
  69. Connect the electrical harness to the RH rear parking brake caliper connector, and then fasten the locking tab.
  70. Install the hub jack adapter onto the RH rear hub, and then installl and hand-tighten the lug nuts that attach the jack adapter to the hub.
  71. Position a support stand under the hub jack adapter and raise the RH rear suspension to approximate ride height.
  72. Adjust the support stand to set the distance from the RH upper fore link to the bolt on the frame rail to 85mm +/-5mm.
  73. Tighten the nut and bolt that attach the RH air spring module to the RH rear knuckle.
  74. Tighten the bolt that attaches the RH upper link to the RH rear knuckle.
  75. Tighten the nut and bolt that attach the RH toe link to the RH rear knuckle.
  76. Remove the support stand from the hub jack adapter.
  77. Remove the lug nuts (x5) that attach the hub jack adapter onto the RH rear hub, and then remove the jack adapter from the hub.
  78. Install the RH rear wheel, and then install the lug nuts (x5).
  79. Install the RH mid aero shield reinforcement to the body, and then install the nuts (x3) and the clip that attach the reinforcement to the body.
  80. Install the LH mid aero shield reinforcement to the body, and then install the nuts (x3) that attach the reinforcement to the body.
  81. Install the mid aero shield to the body, and then install the bolts (x20) that attach the mid aero shield to the body.
  82. Install the LH and RH clips that attach the mid aero shield to the body.
  83. Install the LH shear plate to the body and HV battery, and then install the T25 screws (x3), the 10mm bolt, and a new 15mm nut to attach the shear plate to the body and HV battery.
  84. Install the clips (x2) that attach the LH shear plate to the LH wheel arch liner.
    Note
    2x push clips.
  85. Install the RH shear plate to the body and HV battery, and then install the T25 screws (x3), the 10mm bolt, and a new 15mm nut to attach the shear plate to the body and HV battery.
  86. Install the clips (x2) that attach the RH shear plate to the RH wheel arch liner.
  87. Lower the vehicle, and then tighten the lug nuts (x5) on the RH rear wheel.
  88. Install the lug nut covers (x5) to the RH rear wheel.
  89. Tighten the lug nuts (x5) on the LH rear wheel.
  90. Install the lug nut covers (x5) to the LH rear wheel.
  91. Connect 12V power. See Disconnect 12V Power.
  92. Connect the 12V charger to the vehicle.
  93. Perform a firmware reinstall. See Firmware Reinstall - Touchscreen.
  94. Inspect the coolant level and top off as necessary.
  95. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  96. Unlock the vehicle gateway. See Gateway Unlock.
  97. In Toolbox 3, click the Actions tab, type "Immobilizer Reset" into the search field, click PROC_BCCEN_X_IMMOBILIZER-RESETvia Toolbox:(link), click Run, and allow the routine to complete.
  98. In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Service Mode:Thermal ➜ Actions ➜ Coolant Air Purgevia Toolbox:(link), and click Run.
    Note
    The coolant air purge routine runs for approximately 15 minutes and the coolant level in the reservoir may drop. If the level has stabilized and does not drop further, the routine can be ended early.
  99. Monitor the coolant level and add coolant as needed so that the coolant level remains at the "MAX" line.
    CAUTION
    Do not allow the fluid level to drop below the "MIN" line during the routine, otherwise air will enter the system and the Refill procedure must be repeated starting at step 6.
    Note
    The coolant level should stabilize before the routine ends. If the coolant level is still dropping, perform the routine again.
  100. Install the coolant reservoir cap.
  101. Disconnect the 12V charger from the vehicle.
  102. Install the HEPA filter. See Filter - HEPA (Remove and Replace).
  103. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  104. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  105. Calibrate the falcon doors if necessary.
  106. For China, Japan and Korea only: Carefully remove the old motor label from the hood, and install a new motor label to match the new motor information.
  107. Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.