2025-07-31

Rear Drive Unit - 4DU (Remove and Replace)

Correction code 4001010702 FRT 3.84 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.

Torque Specifications

Table 1. Torque Specifications:Rear Drive Unit - 4DU (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
LH, RH and rear bolts that attach the drive unit to the subframe
80 Nm (59.0 lbs-ft)
  • Ratchet/torque wrench
  • Flex head ratchet/flex head torque wrench
  • 18 mm socket
 Reuse

Remove

  1. While performing the courtesy inspection, note any abnormal tire wear that could indicate the need for an alignment.
  2. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Stands.
  3. Enter Service Mode Plus. See Service Mode Plus.
  4. Select High Voltage > Procedures > Rear Drive Unit Replacement.
  5. From the Before Rear Drive Unit Replacement Action List, click Start Thermal Fluid Fill/Drain (Coolant only), click Run, and allow the routine to complete.
  6. Hold down the brake pedal, from the Before Rear Drive Unit Replacement Action List, click Start EPBR Service Mode, click Run, and allow the routine to complete.
  7. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  8. Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  9. Remove the LH and RH rear suspension covers. See Rear Suspension Cover - LH (Remove and Replace).
  10. Remove the mid aero shield panel. See Aero Shield - Middle (Remove and Replace).
  11. Remove the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  12. Remove the LH and RH rear brake caliper. See Brake Caliper - Rear - LH - Base (Remove and Replace).
  13. Remove bolts securing rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
  14. Remove the HV battery rear skid plate enclosure. See Skid Plate - Rear (Remove and Replace).
  15. Install spring compressor onto RH rear coil spring.
  16. Remove bolt securing LH damper to rear lower aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 115 Nm
  17. Remove bolt securing RH damper to rear lower aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 115 Nm
  18. Position coolant drain container under rear of vehicle
  19. Remove the rear drive unit inverter inlet hose. See Rear Drive Unit Inverter Inlet (Remove and Replace).
  20. Release push clips securing RH rear wheel liner to rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Remove indicated clips and move liner aside for access
  21. Position coolant drain underneath RH rear of HV battery
  22. Disconnect coolant outlet hose to rear return hose and plug hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary, Coolant loss greater than 1 L will require vacuum fill
  23. Release clip securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  24. Remove coolant drain container from underneath vehicle
  25. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  26. Remove rear drive unit HV harness. See High Voltage Harness Rear Drive Unit (Remove and Replace).
  27. Remove HV insulating gloves
  28. Place subframe lifting tool into position underneath rear subframe
  29. Connect air supply to subframe lifting tool
  30. Raise subframe lifting tool to support rear subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    3x straps, Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure, Lower the vehicle if necessary, Recommend assistance
  31. Remove both LH and RH rear shear plate. See Rear Subframe Shear Plate- Front - LH (Remove and Replace).
  32. Remove LH rear bolt securing subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm
  33. Remove RH rear bolt securing subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm
  34. Lower subframe lifting tool to remove subframe from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage components while lowering subframe, Recommended assistance
  35. Disconnect air supply from subframe lifting tool
  36. Position subframe lifting tool and subframe under vehicle
  37. Release RDU logic connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not get coolant ingress into this connector, Move aside as needed
  38. Release RDU logic connection clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  39. Disconnect resolver connector from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x clips
  40. Disconnect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
  41. Remove RDU ground cable clip from subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  42. Remove the bolt that attaches the rear drive unit ground strap to the body.
  43. Release the clips (x2) that attach the rear drive unit inverter outlet to heat exchanger hose to the rear drive unit.
  44. Cut the rear drive unit inverter NVH cover at the line indicated so as to access the clip for the rear drive unit inverter to heat exchanger hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Open the cut in the NVH cover, but be carefull not to remove any of the cover in doing so.
  45. Release the clip, disconnect the rear drive unit inverter to heat exchanger hose from the rear drive unit inverter outlet, and allow to drain.
  46. Release the clip, disconnect the rear drive unit inverter to heat exchanger hose from the rear drive unit heat exchanger, and allow to drain.
  47. Release the remaining clips (x2) that attach the rear drive unit inverter outlet to heat exchanger hose to the rear drive unit, and then manuever the hose out from between the drive unit and rear subframe.
  48. Pull the red tab to release, and then pull the red tab again to disconnect the rear subframe harness from the oil pump connector.
  49. Pull the red tab to release, pull the red tab again to disconnect the rear subframe harness from the resolver connector, and then release the clips (x2) that attach the subframe harness to the rear drive unit.
  50. Remove the bolt that attaches the LH rear wheel speed sensor to LH rear knuckle, and then remove the sensor from the knuckle.
  51. Release the grommet that attaches the LH rear wheel speed sensor harness to LH rear knuckle.
  52. Remove the nut and bolt that attach the LH rear upper aft link to the LH rear knuckle.
  53. Remove the nut and bolt that attach the LH rear upper fore link to the LH rear knuckle.
  54. Remove the nut and bolt that attach the LH rear toe link to the LH rear knuckle.
  55. Loosen, but do not remove, the nut and bolt that attach the LH rear lower fore link to the LH rear knuckle.
  56. Hook the axle remover slide hammer onto the 2 axle remover cable loops, and then use the slide hammer to remove the LH halfshaft from the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be carefull not to damage the halfshaft boots and drive unit seals when separating the halfshaft from the drive unit.
  57. Position the rear subframe assembly under gantry.
  58. Attach the 3 hooks of the drive unit sling tool to the drive unit.
  59. Remove the LH, RH,and rear bolts that attach the drive unit to the subframe.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
    Figure 1. LH Shown, RH Similar
    Figure 2. Rear Bolt
  60. Carefully raise the sling to lift the drive unit out of subframe. As the rear drive unit is lifted, maneuver the half shafts out of the way.
  61. Move the subframe and lifting tool from underneath the drive unit.
  62. Position an empty drive unit crate below the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pallet if no empty crate is available.
  63. Lower the drive unit into the drive unit crate.
  64. Remove the drive unit sling from the gantry and the drive unit.

Install

  1. Position new rear drive unit and crate underneath gantry.
  2. Release protective covers from new rear drive unit and transfer them onto the old drive unit.
  3. Secure drive unit sling onto the new rear drive unit.
  4. Raise the gantry hook to put tension on the sling.
  5. Remove the bolts securing the rear drive unit to the rear drive unit crate.
  6. Lift the new rear drive unit out of the shipping crate.
  7. Lower sling to install drive unit into subframe.
  8. Carefully lower the rear drive unit into the rear subframe. As the rear drive unit is lowered, maneuver the half shafts into the drive unit for later installation.
  9. Hand-tighten the LH, RH and rear bolts that attach the drive unit to subframe.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at a later step.
    Figure 3. LH Shown, RH Similar
    Figure 4. Rear Bolt
  10. Lower the sling to release the tension on the cables.
  11. Torque the LH, RH and rear bolts that attach the drive unit to subframe.
    80 Nm (59.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
  12. Use the shackles (x3) to attach the drive unit sling tool to the old rear drive unit.
  13. Use the gantry to raise the old rear drive unit off of the protective surface and position the drive unit over the rear drive unit crate.
  14. With the help of an assistant, use the gantry to lower the old rear drive unit into the rear drive unit crate.
  15. Install and hand tighten the bolts (x3) that attach the old rear drive unit to the rear drive unit crate.
  16. Remove the drive unit sling tool from the old rear drive unit.
  17. Remove the drive unit sling tool from the gantry.
  18. Prepare the rear drive unit crate for MRB.
  19. With the help of an assistant, slightly rotate the LH halfshaft so as to align the splines of the halfshaft to those in the rear drive unit, lift up on the LH rear knuckle to help move the halfshaft into the drive unit, and then apply force to seat the halfshaft in the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the halfshaft binds, back the halfshaft out, rotate it slightly, and try again.
    Informational PurposesAn informational icon, calling your attention
    Note
    A snap is heard when the retaining clip seats onto the fully inserted halfshaft.
  20. Install the LH rear toe link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
  21. Install the LH rear upper fore link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
  22. Install the LH rear upper aft link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
  23. Fasten the grommet that attaches the LH rear wheel speed sensor harness to LH rear knuckle.
  24. Install the LH rear wheel speed sensor to LH rear knuckle, and then install the bolt that attaches the sensor to knuckle.
    5 Nm (3.7 lbs-ft)
  25. Connect the rear subframe harness to the resolver connector, push the red tab to secure, and then fasten the clips (x2) that attach the subframe harness to the rear drive unit.
  26. Connect the rear subframe harness to the oil pump connector, and then push the red tab to secure.
  27. Manuever the rear drive unit inverter outlet to heat exchanger hose in between the rear drive unit and rear subframe, and then fasten the clips (x2) that attach the hose to the drive unit.
  28. Connect the rear drive unit inverter to heat exchanger hose to the rear drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  29. Connect the rear drive unit inverter to heat exchanger hose to the rear drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  30. Fasten the clips (x2) that attach the rear drive unit inverter outlet to heat exchanger hose to the rear drive unit.
  31. Install the rear drive unit inverter inlet hose. See Rear Drive Unit Inverter Inlet (Remove and Replace).
  32. Connect the rear drive unit coolant outlet hose to the rear drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  33. Install the bolt that attaches the rear drive unit ground strap to the body.
    10 Nm (7.4 lbs-ft)
  34. Fasten the clip that attaches the rear drive unit ground strap to the rear subframe.
  35. Connect air supply to subframe lifting tool
  36. Carefully raise the subframe and rear drive unit assembly until they are up against the body.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage hoses or harnesses while raising the subframe.
  37. Install LH and RH rear bolts securing rear subframe to body hand tight.
    125 Nm (92.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at later step.
  38. Torque boltss securing LH and RH shear plates to vehicle.
    64 Nm (47.2 lbs-ft)
  39. Install clips securing coolant hoses to LH shear plate.
  40. Torque bolt securing subframe and RH rear shear plate to body.
    125 Nm (92.2 lbs-ft)
  41. Release the straps (x3) that attach the rear subframe to the subframe lifting tool.
  42. Lower the subframe lifting tool, and move it out from under the vehicle.
  43. Install rear drive unit HV harness. See High Voltage Harness Rear Drive Unit (Remove and Replace).
  44. Install the rear drive unit inverter inlet hose. See Rear Drive Unit Inverter Inlet (Remove and Replace).
  45. Install the HV battery rear skid plate enclosure. See Skid Plate - Rear (Remove and Replace).
  46. Install rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
  47. Install the LH and RH rear brake caliper. See Brake Caliper - Rear - LH - Base (Remove and Replace).
  48. Install the LH and RH rear suspension covers. See Rear Suspension Cover - LH (Remove and Replace).
  49. Install the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  50. Install the mid aero shield panel. See Aero Shield - Middle (Remove and Replace).
  51. Install the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  52. Perform a cooling system vacuum refill. See .
  53. Connect the LV battery power. See .
  54. Connect an LV maintainer. See .
  55. Reconnect the laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  56. On the touchscreen, select Stop Thermal Fill Drain, click Runto allow the routine to complete.
  57. Select Release / Re-Engage Emergency Parking Brake EPB Service Mode, choose BOTH in EPB Selection tab, select STOP in Action Selection tab, and then click Runto allow the routine to complete.
  58. Select Coolant Air Purge, and then click Runto allow the routine to complete, then click Close.
  59. Select Thermal system Test , and then click Runto allow the routine to complete.
  60. 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.
  61. Disconnect the LV maintainer. See .
  62. Exit Service Mode. See .
  63. Install the HEPA filter assembly See HEPA Filter Assembly (Remove and Replace).
  64. Install the rear underhood apron. See .
  65. Close the hood.
  66. Move both front seats to original position.
  67. Raise all windows and close all doors.
  68. Remove the lift arms from below the vehicle.
  69. 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 correction code as a separate activity to the SV. See Alignment Requirement - Suspension.