02/04/2024 00:58:33

Mount - Clevis - Front Drive Unit - LH (Remove and Replace)

Correction Code 39014302

  • 2024-03-29: Updated procedure to latest validation: no need to remove/install the HV battery.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1081765-00-A 3/4 TON UNDERHOIST STAND
Tesla 1056566-00-A 5MM LOCATING SHIM SET FOR FRONT DU REPLACEMENT
Tesla 1083188-00-B MULTIMETER
Tesla 1032900-01-A HEAT INDUCTOR TOOL (EMEA)
Tesla 1032900-00-A TOOL, INDUCTIVE HEATING (NA, APAC)
Tesla 1134264-00-A DRIVE UNIT OIL DRAIN KIT
1096075-00-A HYDRAULIC HUB PULLER
1498673-00-A CABLE AXLE REMOVAL KIT
1083189-00-A ATF OIL REFILLER

Removal

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Loosen the LH wheel lug nuts (x5).
  3. Loosen the LH front axle nut.
  4. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  5. Remove the HEPA filter.
  6. Remove the 12V battery cage. See Cage - Battery - Auxiliary - 12V (Remove and Replace).
  7. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  8. Remove the bolts (x2) that attach the front bash plate extrusion to the vehicle.
  9. Remove and discard the front HV battery bolts (x4).
  10. Remove upper skid plate bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  11. Remove the skid plate from between the HV battery and the front subframe.
  12. Remove the bolts (x2) that attach the chiller to the vehicle.
  13. Move the chiller slightly to the right of the vehicle to gain access to the FDU acoustic cover.
  14. Unfasten the Velcro straps (x2)
    Informational PurposesAn informational icon, calling your attention
    Note
    Unfasten Velcro straps on the RH FDU acoustic cover and move away to gain access to the drain plug.
  15. Place an oil drain container under the FDU.
  16. Drain the oil from the FDU.
  17. Reinstall the FDU drain plug (torque 28 Nm).
  18. Spray the area with brake cleaner and wipe residual fluid off with a towel.
  19. Install RH FDU acoustic cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x straps
  20. Reinstall the bolts (x2) that attach the chiller to the subframe (torque 12 Nm)
  21. Lower the vehicle to a comfortable working height.
  22. Remove the LH front wheel. See Wheel Assembly (Remove and Install).
  23. Release the LH front wheel speed sensor grommets (x2).
  24. Remove the LH front axle nut and washer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the nut after removal.
  25. Install the hub puller onto the LH front brake rotor.
  26. Use the hub puller to free the LH halfshaft from the hub splines.
  27. Remove the hub puller from the LH hub assembly.
  28. Remove and discard the nut that attaches the LH front upper control arm to the knuckle, and then compress the ball joint downwards to release the bolt.
  29. Remove and discard the LH tie rod nut and move the tie rod end away.
  30. Remove the nut and bolt that attach the LH front air spring module to the front lower aft link.
  31. Remove and discard the nut that attaches the LH stabilizer bar end link to the stabilizer bar and move the end link away from the stabilizer bar.
  32. Remove the LH halfshaft from the LH hub assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the hub puller if more clearance is needed to free the shaft from the knuckle.
  33. Remove the LH halfshaft from the FDU and remove it from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wrap the cable around the inner joint, then tighten it with the U-bolt. Use a slide hammer with cable eyelets to release the halfshaft. To avoid damage to the halfshaft boots and oil seals, exercise caution when removing.
  34. Lower the vehicle partially.
  35. Use the inductive heating tool to heat the bolts (x2) that attach the LH front drive unit clevis to the LH front drive unit isolator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the heating coil around the bolt, and then heat the bolt for 20 seconds. Repeat on the 2nd bolt.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Exercise caution and wear PPE. The bolt becomes extremely hot.
  36. Fully raise the vehicle.
  37. Support the front drive unit with the underhoist stand.
  38. Remove and discard the bolts (x2) that attach the LH front drive unit clevis to the LH front rail.
  39. Remove and discard the bolts (x2) that attach the LH front drive unit clevis to the isolator mount, and then remove the clevis from the vehicle.

Installation

  1. Position the new LH front drive unit clevis on the front drive unit, and then hand-tighten the new bolts that attach the clevis to the isolator.
    Informational PurposesAn informational icon, calling your attention
    Note
    The flat side of the clevis (circled) faces the rear of the vehicle.
    Tip: Adjust the underhoist stand to align the mounting holes.
  2. Loosely thread new bolts (x2) that attach the LH front drive unit clevis to the side rail.
  3. Install shim kit onto RH motor mount
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust Jack if alignment shims do not slide into place easily, Caution by adjusting jack, shims may fall off
  4. Torque the bolts with washers (x2) that attach the LH front drive unit clevis to the LH side rail (torque 65 Nm).
  5. Torque the bolts (x2) that attach the LH front drive unit clevis to the isolator (torque 50 Nm).
  6. Check that the drive unit mount locating shims are able to easily slide in and out of the mounts. If necessary, loosen and re-torque the clevis bolts until the shims easily slide in and out of the mounts.
  7. Remove the drive unit mount locating shims from the vehicle.
  8. Remove the underhoist stand from the working area.
  9. Install the LH front halfshaft into the FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the C-clip opening at the bottom of the axle to ease installation. Make sure that the axle is fully seated into the drive unit. Straighten the axle and apply pressure to the opposite end until an audible click is heard when the C-Clip is fully engaged. If an audible click is not heard, adjust the shaft position and reinstall. Perform a push pull test on the inner part of the shaft to confirm proper installation.
  10. Apply Molykote M-77 to the outboard side of LH axle shaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean if necessary. Apply no more than 1 gram to the axle.
  11. Install the LH halfshaft into the hub and bearing assembly with a new lock washer and hand tighten the nut.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at a later step. Use the nut without the washer to pull the shaft through the hub, then remove the nut and install a new washer. Do not use power tools as the risk of stripping the threads is very high.
  12. Install the bolt and nut that attach the LH front air spring module to the front lower aft link (torque 140 Nm).
  13. Install the bolt and new nut that attach the upper control arm ball joint to the LH front knuckle assembly (torque 60 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold bolt in place to prevent turning while installing the nut.
  14. Install the LH front wheel speed sensor grommets (x2).
  15. Install a new nyloc nut that attaches the LH stabilizer bar to the stabilizer bar end link (torque 70 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Counter hold the stud with a 5mm hex socket.
  16. Install a new nyloc nut that attaches the front tie rod to the LH front knuckle (torque 103 Nm).
  17. Install the LH front wheel. See Wheel Assembly (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Start lug nuts by hand before using power tool
  18. Install the bolts (x2) that attach the skid plate to the front subframe (torque 9 Nm).
  19. Install new patch bolts (x4) that attach the front of the HV battery to the vehicle (torque 30 Nm).
  20. Install the bolts (x2) that attach the front bash plate extrusion (torque 16 Nm).
  21. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  22. Torque the LH front wheel lug nuts (x5, torque 175 Nm).
  23. Torque the LH front axle nut (torque 245 Nm).
  24. Install the LH front wheel center cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify emblem is aligned with valve stem
  25. Install the LH front lug nut covers (x5).
  26. Remove the FDU fill plug.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hex bolt, 8 mm.
  27. Fill FDU with oil.
    Informational PurposesAn informational icon, calling your attention
    Note
    See Fluids for oil types and Fluid Capacities for oil quantities based on front drive unit type.
  28. Install the FDU fill plug (torque 28 Nm).
  29. Install the 12V auxiliary battery cage. See Cage - Battery - Auxiliary - 12V (Remove and Replace).
  30. Connect 12V power. See Disconnect 12V Power.
  31. Install the HEPA filter housing.
  32. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  33. Install the under hood aprons.
  34. Calibrate the falcon doors via the touchscreen.