18/12/2023 04:22:31

Halfshaft - Front Drive Unit - LH (1st Generation) (Remove and Replace)

Correction Code 39302002

  • 2023-12-18: Added step to perform test drive to break in new halfshaft(s).

Special tool(s) required for this procedure:

Supplier Part Number Description
Tesla 1117845-00-A Wheel Lug Nut Removal Tool
Tesla 1082171-00-A Brake Caliper S-Hook
Tesla 1096075-00-A Hydraulic Hub Puller
Tesla 1498673-00-A Axle Remover Cable Kit
Tesla 1053589-00-A Slide hammer

This procedure is for vehicles built through April 24, 2019. For vehicles built after April 24, 2019, SeeHalfshaft - Front Drive Unit - LH (2nd Generation) (Remove and Replace).

Informational PurposesAn informational icon, calling your attention
Note
When installing halfshaft 1553109-00-B or newer: if not already installed, install the updated LH front drive unit axle seal.

Removal

  1. Remove the LH front wheel center cap.
  2. Loosen the LH front axle nut.
  3. Move the vehicle to a 2-post lift.
  4. Disconnect 12V power. See Disconnect 12V Power.
  5. Remove the LH front wheel. See Wheel Assembly (Remove and Install).
  6. Drain the fluid from the front gearbox (refer to procedure).
  7. Remove the bolts (x2) that attach the LH front caliper to the LH front knuckle, remove the caliper from the knuckle, and then use the brake caliper S-hook tool to support the caliper..
  8. Remove the nut and discard the washer that attach the halfshaft to the hub.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut can be reused.
  9. Install the hydraulic hub puller on the LH front brake rotor using 2 lug nuts and 2 hydraulic hub puller washers.
  10. With assistance, separate the halfshaft from the hub splines using the hydraulic hub puller, and then remove the puller from the hub.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    To reduce the risk of personal injury, wear cut resistant gloves and proper personal protective equipment (PPE) as required when removing the halfshaft.
  11. Remove the LH front wheel speed sensor harness from the bracket on the LH front knuckle.
  12. Release the clip that attaches the LH front wheel speed sensor harness to the LH front knuckle.
  13. Remove the bolt and discard the nut that attach the LH front knuckle to the LH front upper control arm ball joint.
  14. Separate the LH front upper control arm from the LH front knuckle.
  15. Remove the bolt and nut that attach the bottom of the LH front air spring module to the LH front lower control arm.
  16. Restrain the LH tie rod ball joint pin, remove and discard the nut that attaches the LH tie rod end to the LH front knuckle, and then move the tie rod end away from the knuckle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To prevent ball joint damage, always hold the ball joint pin with a wrench while loosening the nut.
  17. Remove and discard the nut that attaches the stabilizer bar to the LH stabilizer bar end link, and then move the end link away from the sway bar.
  18. Remove the LH front halfshaft from the LH front hub.
  19. Install the axle removal tool around the inner joint of the LH front halfshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a cable tie to secure the axle removal tool in place.
    Figure 1. Close-up view of axle removal tool on halfshaft
  20. Attach a slide hammer to the axle removal tool, and then use the slide hammer to remove the LH front halfshaft from the front drive unit.
  21. Working from the LH wheelwell, remove the halfshaft from the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To avoid damage to the halfshaft boots and oil seals, exercise caution when removing and installing halfshafts.

Installation

Informational PurposesAn informational icon, calling your attention
Note
When installing halfshaft 1553109-00-B or newer: if not already installed, install the updated LH front drive unit axle seal.
  1. Install the halfshaft into the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    • When installing the halfshaft(s) into the drive unit:
      • Make sure that the opening of the snap ring is facing towards the bottom of the drive unit.
      • Do not damage or displace the oil seal.
      • Verify that the halfshaft is fully seated:
        • Carefully push the halfshaft into the drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
        • There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
        • Pull on the inner halfshaft cup to confirm that the circlip is locked into place. If the halfshaft detaches from the drive unit then reinstall the halfshaft and then test that it is fully seated.
  2. Apply no more than 1 gram of Molykote M-77 lubricant paste only to the hub mating face on the outboard side of the halfshaft.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply any lubricant to the halfshaft splines. If lubricant is mistakenly applied, wipe the splines clean with a shop towel.
  3. Install the halfshaft into the hub, and then hand-tighten the nut and a new washer.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut can be reused.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tightening of the nut will be done a later step.
  4. Install the LH stabilizer bar end link into the stabilizer bar, and then install a new nut to attach the end link to the stabilizer bar (torque 70 Nm).
  5. Install the LH tie rod end into the LH knuckle, install a new nut to attach the LH tie rod end to the knuckle, use a wrench to restrain the LH tie rod end pin, and then tighten the nut (torque 103 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To prevent ball joint damage, always hold the ball joint pin with a wrench while tightening the nut.
  6. Install the bolt and nut that attach the bottom of the LH front air spring module to the LH front lower control arm and hand tighten.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque the bolt in a later step.
  7. Install the LH front upper control arm into the LH front knuckle.
  8. Install the bolt and new nut to attach the LH front knuckle to the LH front upper control arm ball joint (torque 60 Nm).
  9. Fasten the clip that attaches the LH front wheel speed sensor harness to the LH front knuckle.
  10. Install the LH front wheel speed sensor harness into the bracket on the LH front knuckle.
  11. Remove the LH front caliper from the S-hook, install the caliper onto the LH front knuckle, and then install the bolts (x2) that attach the caliper to the knuckle (torque 120 Nm).
  12. Refill the front drive unit with fluid (refer to procedure).
  13. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  14. Install the LH front wheel, but do not install the wheel center cap at this time. See Wheel Assembly (Remove and Install).
  15. Tighten the LH front axle nut (torque 245 Nm).
  16. Install the LH front wheel center cap.
  17. Connect 12V power. See Disconnect 12V Power.
  18. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  19. Move the vehicle to a 4-post lift.
  20. Torque the bolt that attaches the LH front air spring module to the LH front lower control arm (torque 140 Nm).
  21. Remove the vehicle from the 4-post lift.
  22. Perform a test drive to break in the new halfshaft(s).
    Informational PurposesAn informational icon, calling your attention
    Note
    Add correction code 00040100 as a separate activity to the Service Visit.
    1. Make sure that the HV battery SOC is above 70%. Charge the HV battery as necessary.
    2. On the vehicle touchscreen, select Standard or Sport for Acceleration.
    3. Perform a full-throttle acceleration from 0 - 80 kph (0 - 50 mph) for 3 times. Confirm absence of excessive vibrations or shuddering at the front of the vehicle.
      Informational PurposesAn informational icon, calling your attention
      Note
      If vibration or shuddering is noticed, refer to SB-21-39-001 - Replace Front Drive Unit Halfshafts.