2025-10-24

Rear Drive Inverter - 4DU (Remove and Replace)

Correction code 4020010302 FRT 2.76 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2025-10-01: Removed immobilizer/vehicle odometer pairing. Added caution note not to rest inverter on HV lugs. Added more detailed disassembly steps.

Torque Specifications

Table 1. Torque Specifications:Rear Drive Inverter - 4DU (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (X3) securing the rear drive unit 3 phase cable for inverter and motor
5 Nm (3.7 lbs-ft) + 40 degrees
  • 4 in extension
  • 10 mm socket
  • Cordless Ratchet/Impact Driver
 Replace
Bolts (X9) securing the RDU inverter to gearbox assembly
12.5 Nm (9.2 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • 4 in extension
  • External Torx Plus EP10
 Replace

Remove

  1. Inspect the vehicle for abnormal tire wear that might indicate the need for a wheel alignment. Note any findings.
  2. Open all doors and lower all windows.
  3. Move both front seats forward.
  4. Run PROC_PMR_X_STORE-DATA-BOOTvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Store Bootloader Data.
  5. Run PROC_DIR_X_STORE-DATA-APPvia Toolbox: (link)via Service Mode Plus: Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Store Application Data.
  6. Run PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
    .
  7. Remove the diagnostic cable from the port to disconnect Toolbox 3.0 from the vehicle.
  8. Raise and support the vehicle. See Raise Vehicle - 2 Stands.
  9. Disable HV power. See Vehicle HV Disablement Procedure.
  10. Remove the RH rear wheel. See Wheel Assembly (Remove and Install).
  11. Remove the rear aero shield. See Aero Shield - Rear (Remove and Replace).
  12. Remove the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  13. Remove the rear stabar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
  14. Remove the RH 12V subframe harness clip from the body.
  15. Remove the RH 12V subframe harness clip from the rear subframe brace.
  16. Remove the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  17. Remove the LH mount assembly between rear drive unit and subframe. See LHD Mount - 4DU (Remove and Install).
  18. Mark LH rear and RH rear subframe bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, Mark original location of subframe, Re-align during install, Can also mark subframe casting and subframe bushing to body if needed
  19. Remove the LH and RH shear plates. See Rear Subframe Shear Plate- Front - LH (Remove and Replace).
  20. Remove LH and RH rear bolts that attach the subframe to the body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21 mm socket
  21. Remove the rear subframe brace from the rear subframe.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Hold the brace with hands while removing, or there will be a risk of falling.
  22. Put on an ESD wrist strap and secure it to the inverter housing.
  23. Remove the phase cover. See Cover- Phase Out - 4DU (Remove and Replace).
  24. Remove bolts securing the rear drive unit 3 phase cable for inverter and motor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  25. Remove bolts securing the rear drive unit inverter to gearbox assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 4 in extension
    • External Torx Plus EP10
  26. Remove inverter from drive unit and drain coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The inverter must be removed down between the drive unit and subframe. Discard the gasket after removal. Be careful not to damage the PCBA during removal.
  27. Place the drive inverter on ESD mat.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not place inverter facing downwards on the circuit board or HV lugs.
  28. Remove ESD wrist strap from inverter housing.

Install

  1. Secure ESD strap to inverter housing.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clipping location can vary, as long as clip is making proper contact with metal housing.
  2. Clean mating surfaces of the phase lugs and inverter.
  3. Position the inverter with gasket to rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver rear inverter into position, take caution when maneuvering between subframe do not damage the circuit board, make sure the 3 phase cables and guides align during installation, install new gasket.
  4. Hand-tighten the fasteners securing inverter to gearbox assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 4 in extension
    • External Torx Plus EP10
  5. Torque fasteners securing inverter to gearbox assembly.
    12.5 Nm (9.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque the 2 fasteners nearest the alignment dowels first.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 4 in extension
    • External Torx Plus EP10
  6. Install bolts securing the rear drive unit 3 phase cable for inverter and motor.
    5 Nm (3.7 lbs-ft) + 40 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  7. Install the phase out cover to rear drive unit. See Cover- Phase Out - 4DU (Remove and Replace).
  8. Remove ESD wrist strap from inverter.
  9. Install 4DU NVH cover.
  10. Install the LH mount assembly between rear drive unit and subframe. See LHD Mount - 4DU (Remove and Install).
  11. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  12. Raise drive unit and subframe into position.
  13. Install the rear subframe brace to the rear subframe.
  14. Install both LH and RH rear bolts securing rear subframe to body hand tight.
  15. Install the LH and RH shear plates. See Rear Subframe Shear Plate- Front - LH (Remove and Replace).
  16. Position subframe to marked location.
  17. Mark LH rear and RH rear subframe bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, Mark original location of subframe, Re-align during install, Can also mark subframe casting and subframe bushing to body if needed
  18. Torque bolt securing RH rear of subframe to body.
  19. Torque the larger bolt that attaches the LH shear plate to the vehicle, and then mark the bolt with a paint pen after torquing.
    125 Nm (92.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 3 in extension
    • 21 mm socket
    • Ratchet/torque wrench
  20. Torque the smaller bolts that attach the LH shear plate to the HV battery.
    64 Nm (47.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 13 mm socket
    • 3 in extension
    • 6 in extension
    • Flex head ratchet/flex head torque wrench
  21. Lower rear subframe lifting tool from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify yellow safety straps are removed from subframe
  22. Disconnect air supply from subframe lifting tool
  23. Remove subframe lifting tool from underneath vehicle
  24. Connect RDU HV cable to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
  25. Install nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  26. Install clip securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  27. Position coolant drain underneath RH rear of HV battery
  28. Remove plugs and connect RDU inverter inlet hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated,Loss of coolant greater than 1L requires coolant vacuum fill
  29. Remove coolant drain container from underneath vehicle
  30. Install the HV battery rear skid plate enclosure. See Skid Plate - Rear (Remove and Replace).
  31. Install bolts securing rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
  32. Install the rear fascia. See Assembly - Fascia and Diffuser - Rear (Remove and Install).
  33. Perform cooling system refill. See Cooling System (Drain and refill).
  34. Connect an LV maintainer. See .
  35. Unlock the vehicle gateway. See .
  36. On the touchscreen, tap Service mode Plus High Voltage > Procedures > Rear Drive Inverter Replacement, and then allow the routine to complete.
  37. Select Stop Thermal Fill Drain, click Runto allow the routine to complete.
  38. Select Restore Bootloader Data, click Runto allow the routine to complete.
  39. Select CAN Redeploy, click Runto allow the routine to complete,then click Close.
  40. Select Restore Application Data, and then click Runto allow the routine to complete, then click Close.
  41. Select Coolant Air Purge, and then click Runto allow the routine to complete.
  42. Disconnect the LV maintainer. See .
  43. Connect the LV battery power. See .
  44. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  45. Install the HEPA filter assembly See HEPA Filter Assembly (Remove and Replace).
  46. Install the rear underhood apron. See .
  47. Select Thermal system Test , and then click Runto allow the routine to complete.
  48. Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn.
  49. Select Resolver Error Learn, and then click Runto allow the routine to complete.
  50. Disable Service Mode. See .
  51. Remove safety stanchions from around vehicle after resolver learn is completed.
  52. Lower vehicle fully.
  53. Raise all windows and close all doors.
  54. Remove the lift arms from below the vehicle.
  55. 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.