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.NOTE:
See Ergonomic Precautionsfor safe
and healthy working practices.
- 2025-09-30: Added steps to disconnect/reconnect RDU ground strap from body. Added links to automated routines. Added missing subframe fastening steps during install. Added ride height adjustment process. Added steps for adding and removing 12V subframe harness and RSF brace. Updated mislabeled hose names. Reordered steps for 4DU.
Torque Specifications
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) |
|
Reuse |
Remove
- While performing the courtesy inspection, note any abnormal tire wear that could indicate the need for an alignment.
- Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Stands.
- Enter Service Mode Plus. See Service Mode Plus.
- Select .
-
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
-
PROC_EPB_X_SERVICE-MODEvia Toolbox: (link)via Service Mode:
- Chassis ➜ Brakes ➜ EPB Service Mode
- Chassis ➜ Brakes ➜ EPB Service Mode
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
- Remove the LH and RH rear suspension covers. See Rear Suspension Cover - LH (Remove and Replace).
- Remove the mid aero shield panel. See Aero Shield - Rear (Remove and Replace).
- Remove the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
-
Remove the nut securing the rear drive unit ground strap to the body.
- Remove the rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
-
Remove the RH 12V subframe harness clip from the body.
-
Remove the RH 12V subframe harness clip from the rear subframe brace.
-
Disconnect the RH side 12V subframe harness connector.
- Remove the LH and RH rear brake caliper from the knuckle and hang it from the body. See Brake Caliper - Rear - LH - Base (Remove and Replace).
- Remove the HV battery rear skid plate enclosure. See Skid Plate - Rear (Remove and Replace).
-
Install spring compressor onto the LH
and RH rear coil springs with the notched plate on top.
-
Remove bolt securing LH damper to rear
lower aft link
Note1x bolt, 21 mm, 115 Nm
-
Remove bolt securing RH damper to rear
lower aft link
Note1x bolt, 21mm, 115 Nm
-
Position coolant drain container under
rear of vehicle
- Remove the rear drive unit inverter inlet hose. See Rear Drive Unit Inverter Inlet (Remove and Replace).
-
Release push clips securing RH rear
wheel liner to rocker panel
Note2x clips, Remove indicated clips and move liner aside for access
-
Position coolant drain underneath RH
rear of HV battery
-
Disconnect coolant outlet hose to rear
return hose and plug hoses.
Note1x 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.
-
Release clip securing coolant hoses to
RH shear plate
Note1x fir tree clip
-
Remove coolant drain container from
underneath vehicle
-
Put on HV insulating gloves and
leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
- Remove rear drive unit HV harness. See High Voltage Harness Rear Drive Unit (Remove and Replace).
- Remove HV insulating gloves.
-
Place subframe lifting tool into
position underneath rear subframe.
.
-
Connect the air supply to the subframe
lifting tool.
-
Raise subframe lifting tool to support
rear subframe.
Note3x 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
- Remove both LH and RH rear shear plate. See Rear Subframe Shear Plate- Front - LH (Remove and Replace).
-
Mark the LH and RH rear subframe bolts with the original location of the
subframe.
NoteThe subframe casting and subframe bushing to the body can be marked if needed.
-
Remove LH rear bolt securing the
subframe to the body.
Note1x bolt, 21mm, 125 Nm
-
Remove RH rear bolt securing subframe
to body
Note1x bolt, 21mm, 125 Nm
-
Remove the rear subframe brace from the rear subframe.
CAUTIONUse an assisted lift to avoid dropping the component.
-
Lower the subframe lifting tool to
remove subframe from vehicle.
CAUTIONAssistance is recommended to avoid damaging components.
-
Disconnect air supply from subframe
lifting tool
- Position the subframe lifting tool and subframe away from the vehicle.
-
Release the RDU logic
connection.
NoteDo not allow coolant to ingress into this connector. Move aside as needed.
-
Release the RDU logic connection
clip.
-
Disconnect the resolver connector from
the rear drive unit.
Note1x connector, 2x clips
-
Disconnect the oil pump
connector.
Do not push down on red tab. Pull the red tab to disengage the lock. Pull again to release the connector.
-
Remove the RDU ground cable clip from
the subframe.
-
Remove the bolt that attaches the rear
drive unit ground strap to the body.
-
Position a fluid catcher under the subframe and fixture assembly.
TIpUse a foldable funnel as required
-
Release the PT outlet hose from the heat exchanger.
-
Release the 3x clips securing the PT outlet hose and remove it from the
subframe.
-
Release the clips (x2) that attach the
PT inverter to oil cooler hose to the rear drive unit.
-
Cut the rear drive unit inverter NVH
cover at the line indicated to access the clip for the rear drive unit inverter to heat
exchanger hose.
CAUTIONOpen the cut in the NVH cover, but be careful not to remove any of the cover in doing so.
-
Release the clip, disconnect the rear
drive unit inverter to heat exchanger hose from the rear drive unit inverter outlet, and
allow to drain.
-
Release the clip, disconnect the PT
invert to oil cooler hose from the oil cooler, and allow to drain.
-
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.
-
Pull the red tab to release, and then
pull the red tab again to disconnect the rear subframe harness from the oil pump
connector.
-
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.
-
Remove the bolt that attaches the LH
rear wheel speed sensor to LH rear knuckle, and then remove the sensor from the
knuckle.
-
Release the grommet that attaches the
LH rear wheel speed sensor harness to LH rear knuckle.
-
Remove the nut and bolt that attach
the LH rear upper aft link to the LH rear knuckle.
-
Remove the nut and bolt that attach
the LH rear upper fore link to the LH rear knuckle.
-
Remove the nut and bolt that attach
the LH rear toe link to the LH rear knuckle.
-
Loosen, but do not remove, the nut and
bolt that attach the LH rear lower fore link to the LH rear knuckle.
-
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.
NoteBe careful not to damage the halfshaft boots and drive unit seals when separating the halfshaft from the drive unit.
-
Hook the axle remover slide hammer onto the 2 axle remover cable loops, and then use
the slide hammer to remove the RH halfshaft from the rear drive unit.
NoteBe careful not to damage the halfshaft boots and drive unit seals when separating the halfshaft from the drive unit.
-
Position the rear subframe assembly
under a gantry.
-
Attach the 3 hooks of the drive unit
sling tool to the drive unit, then raise the sling so there is slight tension on the
cables.
-
Remove the LH, RH,and rear bolts that
attach the drive unit to the subframe.
TIpUse 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 -
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.
- Move the subframe and lifting tool from underneath the drive unit.
-
Position an empty drive unit crate
below the drive unit.
NoteUse a pallet if an empty crate is not available.
- Lower the drive unit into the empty drive unit crate.
- Remove the drive unit sling from the drive unit.
Install
- Position new rear drive unit and crate underneath gantry.
-
Release protective covers from new
rear drive unit and transfer them onto the old drive unit.
-
Secure the drive unit sling onto the
new rear drive unit.
-
Raise the gantry hook to put tension
on the sling.
-
Remove the bolts securing the rear
drive unit to the rear drive unit crate.
-
Lift the new rear drive unit out of
the shipping crate.
- Lower the sling to install the drive unit into the subframe.
-
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.
-
Hand-tighten the LH, RH and rear bolts
that attach the drive unit to subframe.
TIpUse of the following tool(s) is recommended:
- Ratchet/torque wrench
- Flex head ratchet/flex head torque wrench
- 18 mm socket
NoteTorque at a later step.Figure 3. LH Shown, RH Similar Figure 4. Rear Bolt - Lower the sling to release the tension on the cables.
-
Torque the LH, RH and rear bolts that
attach the drive unit to subframe.80 Nm (59.0 lbs-ft)TIpUse of the following tool(s) is recommended:
- Ratchet/torque wrench
- Flex head ratchet/flex head torque wrench
- 18 mm socket
-
Use the shackles (x3) to attach the
drive unit sling tool to the old rear drive unit.
-
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.
-
With the help of an assistant, use the
gantry to lower the old rear drive unit into the rear drive unit crate.
-
Install and hand tighten the bolts
(x3) that attach the old rear drive unit to the rear drive unit crate.
-
Remove the drive unit sling tool from
the old rear drive unit.
-
Remove the drive unit sling tool from
the gantry.
-
Prepare the rear drive unit crate for
MRB.
- Move the subframe assembly away from under the gantry.
-
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.
CAUTIONDo not force the two assemblies together if they are not aligned correctly. Lift up on the knuckle as needed.NoteIf the halfshaft binds, back the halfshaft out, rotate it slightly, and try again.NoteA snap is heard when the retaining clip seats onto the fully inserted halfshaft.
-
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.
-
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.
-
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.
-
Fasten the grommet that attaches the
LH rear wheel speed sensor harness to LH rear knuckle.
-
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)
- Repeat the previous 6 steps for the RH assemblies.
-
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.
-
Connect the rear subframe harness to
the oil pump connector, and then push the red tab to secure.
-
Manuever the PT inverter to oil cooler
hose in between the rear drive unit and rear subframe, and then fasten the clips (x2)
that attach the hose to the drive unit.
-
Connect the PT inverter to oil cooler
hose onto the oil cooler, fasten the clip, and then perform a Push-Pull-Push check of
the fitting.
-
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.
-
Fasten the clips (x2) that attach the
rear drive unit inverter outlet to heat exchanger hose to the rear drive unit.
- Install the rear drive unit inverter inlet hose. See Rear Drive Unit Inverter Inlet (Remove and Replace).
-
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.
-
Install the bolt that attaches the
rear drive unit ground strap to the body.10 Nm (7.4 lbs-ft)
-
Fasten the clip that attaches the rear
drive unit ground strap to the rear subframe.
-
Connect the RDU logic connector.
-
Connect the RDU logic connection clip.
- Position the subframe and drive unit assembly under the vehicle.
-
Connect air supply to subframe lifting
tool
-
Carefully raise the subframe and rear
drive unit assembly until they are up against the body.
CAUTIONDo not damage hoses or harnesses while raising the subframe.
- Install the rear subframe brace.
-
Install LH and RH rear bolts securing
rear subframe to body hand tight.
NoteTorque at later step.
-
Install LH bolts securing shear plate to HV battery hand tight.
NoteTorque at later step.
- Install bolt and shear plate to LH side of rear subframe hand tight.
-
Install RH bolts securing shear plate to HV battery hand tight.
NoteTorque at later step.
- Install bolt and shear plate to RH side of rear subframe hand tight.
-
Align the subframe to the body using the previously marked locations. Return it as
close to the original position as possible.
-
Torque 2x bolts securing LH shear
plates to vehicle.64 Nm (47.2 lbs-ft)
- Install clips securing coolant hoses to LH shear plate.
-
Torque bolt securing subframe and LH
rear shear plate to body.125 Nm (92.2 lbs-ft)
-
Torque 2x bolts securing RH shear plates to vehicle.64 Nm (47.2 lbs-ft)
- Install clips securing coolant hoses to RH shear plate.
-
Torque bolt securing subframe and RH rear shear plate to body.125 Nm (92.2 lbs-ft)
-
Release the straps (x3) that attach
the rear subframe to the subframe lifting tool.
-
Lower the subframe lifting tool, and
move it out from under the vehicle.
- Install rear drive unit HV harness. See High Voltage Harness Rear Drive Unit (Remove and Replace).
-
Remove the plugs from the coolant outlet hose, then reconnect it.
Note1x 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.
-
Secure the 2x push clips to attach the rear wheel liners to rocker panels.
- Install the rear drive unit inverter inlet hose. See Rear Drive Unit Inverter Inlet (Remove and Replace).
- Install the HV battery rear skid plate enclosure. See Skid Plate - Rear (Remove and Replace).
- Install rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
-
Install the RH 12V subframe harness clip into the rear subframe brace.
-
Install the RH 12V subframe harness clip into the body.
-
Connect the RH side 12V subframe harness connector.
-
Install the nut to secure the rear drive unit ground strap to the body.10 Nm (7.4 lbs-ft)
- Install the LH and RH rear brake caliper. See Brake Caliper - Rear - LH - Base (Remove and Replace).
-
Install and torque bolt securing the
LH damper to the rear lower aft link.
115 Nm (84.8 lbs-ft)Note1x bolt, 21 mm, mark with paint pen.
-
Install and torque the bolt securing
RH damper to rear lower aft link
115 Nm (84.8 lbs-ft)Note1x bolt, 21 mm, mark with paint pen.
-
Install the hub jack adapter onto the
LH rear hub. Hand tighten the 5x lug nuts.
NoteIf the hub adapter already has a pre-drilled hole, there is no need to remove the rotor fastening bolt. If the hub adapter does not have a pre-drilled hole, remove the bolt securing the rotor to the hub before installing the hub jack adapter.
-
Position the under-hoist stand beneath
the hub jack adapter.
-
Make sure the distance from the bottom
of the LH rear quarter panel to the center of the axel is 428 mm.
-
Torque the bolt securing the LH rear
upper aft link to the subframe.
Note21 mm, 1x bolt, 1x nut. Mark with paint pen.134 Nm (98.8 lbs-ft)
-
Torque the bolt securing the LH rear lower aft link to the subframe.115 Nm (84.8 lbs-ft)Note1x bolt. 21 mm. Mark with paint pen.
-
Torque the nut securing the LH rear toe link to the subframe.
85 Nm (62.7 lbs-ft)Note1x nut. 18 mm. Mark with paint pen.
-
Torque the bolt securing the LH rear upper fore link to the subframe.84 Nm (61.9 lbs-ft)
-
Torque the bolt securing the LH rear lower fore link to the subframe.
76 Nm (56.0 lbs-ft)Note1x bolt. 18 mm. Mark with paint pen.
- Remove the support stand from underneath the LH rear hub jack adapter and remove the hub jack adapter from the LH rear hub.
-
Install and torque the bolt securing the LH rear rotor to the LH rear hub if was
removed.5 Nm (3.7 lbs-ft)
- Repeat the previous 10 steps for the RH side.
-
Remove the spring compressors from the LH and RH rear coil springs.
- Install the LH and RH rear suspension covers. See Rear Suspension Cover - LH (Remove and Replace).
- Install the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
- Install the mid aero shield panel. See Aero Shield - Rear (Remove and Replace).
- Install the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
- Reinstall the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
- Perform a cooling system vacuum refill. See .
- Connect the LV battery power. See .
- Connect an LV maintainer. See .
- Reconnect the laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
-
Run PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:
- Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
- Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
- Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
- Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
-
Run PROC_EPB_X_SERVICE-MODEvia Toolbox: (link)via Service Mode:
- Chassis ➜ Brakes ➜ EPB Service Mode
- Chassis ➜ Brakes ➜ EPB Service Mode
-
Run UPDATE_CAN-REDEPLOYvia Toolbox: (link)via Service Mode Plus:
- Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
- Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
- Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
- Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
- Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
- Thermal ➜ HVAC ➜ CAN Redeploy
- chassis ➜ DPB Post Replacement ➜ CAN Redeploy
- chassis ➜ ESP Post Replacement ➜ CAN Redeploy
- chassis ➜ IDB Post Replacement ➜ CAN Redeploy
- chassis ➜ RCU Post Replacement ➜ CAN Redeploy
- chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
- chassis ➜ IBST Replacement Panel ➜ CAN Redeploy
-
Run TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
- Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
- Thermal ➜ Coolant System ➜ Coolant Purge Start
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
- Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
-
Run TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
- Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
- Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
- Disconnect the LV maintainer. See .
-
Inspect the coolant level, top off as
necessary, and then install the coolant bottle cap.
NoteEnsure that the coolant level is at the "Max" line.
- Exit Service Mode. See .
- Install the HEPA filter assembly See HEPA Filter Assembly (Remove and Replace).
- Install the rear underhood apron. See .
- Close the hood.
- Move both front seats to original position.
- Raise all windows and close all doors.
- Remove the lift arms from below the vehicle.
- 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 service visit. See Alignment Requirement - Suspension.