2025-01-23

Inverter - Front Drive Unit (Remove and Replace)

Correction code 3920010302 FRT 2.9 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 LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

Torque Specifications

Table 1. Torque Specifications: Inverter - Front Drive Unit (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x2) that attach the phase out cover to the front drive unit gearbox
14 Nm (10.3 lbs-ft)
  • External Torx Plus EP10
 Reuse
Bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals
11.5 Nm (8.5 lbs-ft)
  • 10 mm deep socket
 Reuse
Bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox
12.5 Nm (9.2 lbs-ft)
  • External Torx Plus EP10
 Reuse

Remove

  1. While performing the courtesy inspection, note any abnormal tire wear that could indicate the need for an alignment.
  2. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
    Informational PurposesAn informational icon, calling your attention
    Note
    Upon successful connection, Service Mode Plus will be enabled, and the "Service Mode Plus" watermark will appear on the touchscreen.
  3. On the touchscreen, touch Service Mode Plus > High Voltage > Procedures > Front Drive Inverter Replacement, then perform the following steps.
    1. Select Store Bootloader Data, select Run, then allow the routine to complete.
    2. Select Store Application Data, select Run, then allow the routine to complete.
    3. Select Start Thermal Fluid Fill/Drain, select Run, and then allow the routine to complete.
  4. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  5. Remove the LH front drive unit mount. See Front Drive Unit Assembly - Left Hand Mount Assembly - 3DU (RI).
  6. Move a coolant catcher under the front subframe and fixture assembly.
  7. Release the clips, disconnect the front drive unit inverter to oil cooler hose from the front drive unit inverter and the oil cooler, plug the inverter fittings, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel as required.
  8. Release the clip that attaches the front drive unit inverter to oil cooler hose to the front drive unit, and then remove the hose from the front drive unit.
  9. Release the clip, disconnect the front drive unit inverter inlet hose from the front drive unit inverter inlet, plug the inverter fitting, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel as required.
  10. Release the clips (x2) that attach the front drive unit inverter inlet hose to the front drive unit, and then remove the hose from the drive unit.
  11. Remove the coolant catcher from under the front subframe and fixture assembly.
  12. Attach an Electrostatic Discharge (ESD) wrist strap to the front drive unit inverter housing.
  13. Remove and discard the front drive unit phase out cover label.
  14. Remove the bolts (x2) that attach the phase out cover to the front drive unit gearbox, and then use a plastic trim tool to remove the cover from the gearbox.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  15. Inspect the condition of the phase out cover and O-rings. If the cover or O-rings are damaged, discard the cover and use a new cover for installation.
  16. Remove the bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If any bolts are dropped into the gearbox housing, they must be retrieved.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
  17. Remove the bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  18. Carefully remove the inverter assembly from the front drive unit, remove the plugs, and allow the coolant to drain.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care of not damaging the circuit board.
  19. Remove the ESD wrist strap from the inverter.
  20. Inspect the front drive unit gearbox housing to make sure that there is no gap pad stuck there. If there is, remove the gap pad, clean the area with an alcohol wipe, and allow at least one minute to dry.

Install

  1. Secure the ESD strap to the new inverter housing.
  2. Use an IPA wipe to clean the HV mating surfaces of the front drive unit motor and front drive unit inverter phase out terminals.
  3. Inspect the condition of the gap pad on the inverter PCB. Replace the gap pad if it does not fulfill these criteria:
    • Undamaged condition.
    • Fully covers the discharge resistor array and no resistors are visible.
    • Clean and free of debris.
    • Evenly adhered to the inverter PCB.
  4. Carefully align the front drive unit inverter to the pins in the front drive unit, and then install the inverter onto the drive unit. Make sure that the phase out terminals align during installation.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid damage to the printed circuit board of the inverter.
  5. Hand-tighten the bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox.
  6. Tighten the bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox.
    12.5 Nm (9.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  7. Install and hand-tighten the bolts (x3) that attach the front drive unit phase out terminals to the front drive unit inverter phase out terminals.
  8. Tighten the bolts (x3) that attach the front drive unit motor phase out terminals to the front drive unit inverter phase out terminals.
    11.5 Nm (8.5 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If any bolts are dropped into the gearbox housing, they must be retrieved.
    Informational PurposesAn informational icon, calling your attention
    Note
    If installing a new bolt, tighten to 12.5 Nm, back off 180 degrees, then torque to 5 Nm +40 degrees.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
  9. Lightly lubricate the front drive unit gearbox phase out cover bores with KAF 1 gearbox fluid, and if a new phase out cover is to be installed, lightly lubricate the O-rings of the cover.
  10. Install the phase out cover into the front drive unit gearbox, and then install the bolts (x2) that attach the phase out cover to the front drive unit gearbox.
    14 Nm (10.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  11. Apply a new front drive unit inverter phase out cover label.
  12. Remove the ESD wrist strap from the inverter.
  13. Attach the ESD wrist strap to the old inverter, place the old inverter into the ESD return box, and then remove the ESD wrist strap from the old inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Label and MRB the old inverter.
  14. Perform the inverter air leak test. See Inverter Air Leak Test.
  15. Install the front drive unit inverter inlet hose to the front drive unit, and then fasten the clips (x2) that attach the hose to the drive unit.
  16. Connect the front drive unit inverter inlet hose to the front drive unit inverter inlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  17. Install the front drive unit inverter to oil cooler hose to the front drive unit, and then fasten the clip that attaches the hose to the drive unit.
  18. Connect the front drive unit inverter to oil cooler hose to the front drive unit inverter and the oil cooler, fasten the clips, and then perform a Push-Pull-Push check of the fittings.
  19. Install the LH front drive unit mount. See Front Drive Unit Assembly - Left Hand Mount Assembly - 3DU (RI).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not connect the LV power at this time.
  20. Connect an LV maintainer to the vehicle, and keep the LV power disconnected. See LV Maintainer (Connect and Disconnect) (Maintenance)
  21. Remove the steering wheel lock from the steering wheel.
  22. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  23. On the touchscreen, perform the following steps.
    1. Select Stop Thermal Fluid Fill/Drain, select Run, then allow the routine to complete.
    2. Select Restore Bootloader Data, select Run, then allow the routine to complete.
    3. Select CAN Redeploy, select Run, then allow the routine to complete.
    4. Select Restore Application Data, select Run,then allow the routine to complete.
    5. Select Coolant Air Purge, select Run,then allow the routine to complete.
    6. Select Thermal System Test, select Run,then allow the routine to complete.
  24. Disconnect the LV maintainer from the vehicle. See LV Maintainer (Connect and Disconnect) (Maintenance)
  25. Inspect the coolant level and top up if 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L will require vacuum fill.
  26. Install the front underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  27. Connect the LV power. See LV Power (Disconnect and Connect).
  28. Place stanchions around the vehicle to setup a safety perimeter.
  29. Press the brake pedal to ensure the drive rails are on.
  30. On the touchscreen, select Resolver Error Learn, select Run, and allow the routine to complete.
  31. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  32. Exit Service Mode. See Service Mode.
  33. Remove the stanchions from around the vehicle after the Resolve Error Learn routine is completed.
  34. Install the 2nd row seat cushion. See 2ND ROW SEAT CUSHION (Remove and Replace).
  35. Remove the vehicle from the lift.
  36. In this procedure, the front or rear subframe was removed and reinstalled. Therefore, 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.