04/11/2024 04:51:59

Halfshaft - Front Drive Unit - LH (2nd Generation) (Remove and Replace)

Correction Code 39303102

  • 2024-04-10: Changed the steps of using a S-hook to steps of removing the bolt that attaches the brake jounce hose bracket to the LH air spring module.
  • 2023-12-14: Added step to perform test drive to break in new halfshaft(s).
  • 2023-05-05: Added step to reinstall the front brake caliper.
  • 2023-04-17: Added a video at Step 18 in Removal part to demonstrate the use of the axle removal tool.

Special tool(s) required for this procedure:

Supplier Part Number Description
Tesla 1117845-00-A Wheel Lug Nut Removal Tool
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 after April 24, 2019. For vehicles built through April 24, 2019, See Halfshaft - Front Drive Unit - LH (1st Generation) (Remove and Replace).

Removal

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift .
  2. Remove the LH front wheel center cap from the vehicle using a suction cup clamp.
  3. Loosen the LH front axle nut, but do not remove it yet.
  4. Remove the LH front lug nut covers from the LH front wheel using the wheel nut cover removal tool.
  5. Remove the LH front wheel. See Wheel Assembly (Remove and Install) .
  6. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  7. Remove and discard the bolt that attaches the LH wheel speed sensor to the knuckle.
  8. Release the grommet and clip that attach the LH wheel speed sensor harness to the knuckle, and then set the sensor aside.
  9. Remove and discard the nut that attaches the stabilizer bar to the stabilizer bar end links.
    Informational PurposesAn informational icon, calling your attention
    Note
    Counter hold the stud with a 5mm hex socket and use wrench to remove the nut.
  10. Restrain the tie rod ball joint pin, and then remove and discard the nut that attaches the LH tie rod end to the knuckle. Move the tie rod end away afterward.
    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 lock nut.
  11. Remove the bolt that attaches the brake jounce hose bracket to the LH air spring module.
  12. (1420113-00-B and newer only): Remove the bolt and nut that attach the bottom of the LH front air spring module to the LH front lower control arm.
    Informational PurposesAn informational icon, calling your attention
    Note
    This step is only necessary for halfshaft 1420113-00-B and newer. These halfshafts have a larger CV housing that require more room for access.
  13. Remove the bolt and nut that attach the knuckle to the upper control arm ball joint, and then discard the nut after removal.
  14. Disconnect the upper control arm from the knuckle.
  15. 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.
  16. Install the hydraulic hub puller on the LH front brake rotor using 2 lug nuts and 2 hydraulic hub puller washers.
  17. Separate the halfshaft from the hub splines using the hydraulic hub puller, and then remove the puller from the hub.
  18. With assistance, remove the halfshaft 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. Keep hands clear from other components to prevent injury when the halfshaft releases from the Drive Unit.
  19. Remove the hub puller from the LH hub assembly.
  20. Install the axle removal tool around the inner joint of the 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
  21. Attach a slide hammer to the axle removal tool, and then use the slide hammer to remove the halfshaft from the vehicle.

Installation

  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. Align the splines of the LH front halfshaft with those of the LH front hub, and then install the halfshaft into the hub.
  4. Install only the axle nut onto the halfshaft, and then use a ratchet and socket to manually tighten the nut to pull the halfshaft into the hub until it seats.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not use power tools to tighten the nut as it might strip the threads.
  5. Remove the axle nut from the halfshaft, install a new washer onto the halfshaft, and then reinstall the axle nut hand tightened.
    Informational PurposesAn informational icon, calling your attention
    Note
    The axle nut is torqued in a later step.
  6. Install the bolt and a new nut that attach the knuckle to the upper control arm ball joint (torque 60 Nm).
  7. (1420113-00-B and newer only): Move the LH front air spring module into position, and then hand-tighten the bolt and nut that attach the air spring module to the LH front lower control arm.
    Informational PurposesAn informational icon, calling your attention
    Note
    This step is only necessary for halfshaft 1420113-00-B and newer. These halfshafts have a larger CV housing that require more room for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    This joint is torqued in a later step.
  8. Install the bolt that attaches the brake jounce hose bracket to the LH air spring module (torque 6 Nm).
  9. Restrain the tie rod ball joint pin, and then install a new nut that attaches the LH tie rod end to the knuckle (torque 103 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    To prevent ball joint damage, always hold the ball joint pin with a wrench while tightening the lock nut.
  10. Install new nut that attaches the stabilizer bar to the stabilizer bar end links (torque 70 Nm).
  11. Install the grommet and clip that attach the LH wheel speed sensor to the knuckle.
  12. Install a new bolt that attaches the LH wheel speed sensor to the knuckle (torque 5 Nm).
  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. Install the LH front lug nut covers (x5).
  16. Tighten the LH front axle nut (torque 245 Nm).
  17. Install the LH front wheel center cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the emblem is aligned with the valve stem.
  18. Remove the vehicle from the lift.
  19. Halfshafts 1420113-00-B and newer only:
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform the following steps only if the front air spring to front lower control arm joint was loosened.
    1. Move the vehicle to a 4-post lift.
    2. Torque the bolt that attaches the LH front air spring module to the LH front lower control arm (torque 140 Nm). Mark the nut with a paint pen.
    3. Remove the vehicle from the 4-post lift.
  20. 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.