2024-12-24

Rear Drive Inverter (3DU) (Remove and Install)

Correction code TBD FRT 2.52 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: Rear Drive Inverter (3DU) (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the RDU ground strap to the vehicle
10 Nm (7.4 lbs-ft)
  • 10 mm 12-point deep socket
 Reuse
LH and RH rear bolts that attach the subframe to the body
125 Nm (92.2 lbs-ft)
  • 21 mm socket
 Reuse
Bolts (x2) that secure the RDU phase out cover
14 Nm (10.3 lbs-ft)
  • External Torx Plus EP10
 Reuse
Bolts (x3) that attach the RDU 3-phase cable to the inverter and motor
11.5 Nm (8.5 lbs-ft)
  • 10 mm socket
 Reuse
Bolts (x12) that attach the RDU inverter to the gearcase assembly
12.5 Nm (9.2 lbs-ft)
  • External Torx Plus EP10
 Reuse

Remove

  1. Inspect the vehicle for abnormal tire wear that might indicate the need for a wheel alignment. Note any findings.
  2. Place the vehicle on the 2-post lift.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Ensure the vehicle is not charging.
  3. Open all doors and lower all windows.
  4. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  5. Unlock the vehicle gateway. See Gateway (Unlock).
  6. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Start Thermal Fill/Drain > Run, and allow the routine to complete.
  7. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  8. Remove both rear wheels. See Wheel Assembly (Remove and Install).
  9. Remove the rear fascia diffuser. See Rear Fascia - Diffuser (Remove and Replace).
  10. Remove the nut that attaches the RDU (rear drive unit) ground strap to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  11. Remove the rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear - 23.6MM X 3.5MM (Remove and Replace).
  12. Remove the support stand from the front portion of the rear subframe.
  13. Remove the RH side 12V subframe harness clip from the body.
  14. Remove the RH side 12V subframe harness clip from the RSF brace.
  15. Release the clips (x2) that attach the coolant hoses to the LH shear plate.
  16. Remove the RDU inverter inlet hose. See TUBE (PT), RDU INVERTER INLET, M3 (Remove and Replace).
  17. Release the clip that attaches the coolant hoses to the RH shear plate.
  18. Remove the coolant drain container from underneath the vehicle.
  19. Remove the RDU HV harness. See HV Harness - Rear Drive Unit (3DU) (Remove and Replace).
  20. Remove the HV insulating gloves.
  21. Release the RDU logic connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow coolant to enter into the connector. Move it aside as needed.
  22. Release the RDU logic connector clip.
  23. Place the subframe lifting tool into position underneath the rear subframe.
  24. Connect the air supply to the subframe lifting tool.
  25. With assistance, raise the subframe lifting tool to support the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach the metal hooks (x3) at the end of straps to rings on the subframe lifting tool, and pull the straps until secure. Lower the vehicle if necessary.
  26. 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
  27. Remove the LH and RH shear plates. See REAR SUBFRAME SHEAR PLATE- FRONT - LEFT HAND (Remove and Replace).
  28. 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
  29. Remove the RSF (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.
  30. With assistance, partially lower the rear subframe and drive unit assembly to gain access to the inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while lowering the subframe as multiple components are still attached. Do not overstrain the components.
    Informational PurposesAn informational icon, calling your attention
    Note
    The dampers and the brake calipers are still connected. Recommend to lower about 3.25in or 8.25cm.
  31. Remove the LH mount assembly. See Rear Drive Unit Assembly - 3DU - Drive Unit - LH Mount - 3DU (Remove and Replace).
  32. Remove the cooler hose from the motor mount.
  33. Put on an ESD wrist strap and secure it to the inverter housing.
  34. Remove and discard the phase cover label.
  35. Remove the bolts (x2) that secure the RDU phase out cover.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  36. Remove the phase out cover from the RDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to aid in removal.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the phase out cover or the O-rings are damaged, replace with a new unit.
  37. Remove the bolts (x3) that attach the RDU 3-phase cable to the inverter and motor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  38. Remove the bolts (x12) that attach the RDU inverter to the gearcase assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  39. Remove the inverter from the drive unit and drain the coolant.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the inverter down between the drive unit and subframe. Be careful not to damage the PCBA during removal.
  40. Place the drive inverter on an ESD mat.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not place the inverter facing downwards on the circuit board as it is fragile.
  41. Keep the ESD wrist strap onto the inverter housing and discard the gasket.

Install

  1. Use IPA wipes to clean the mating surfaces of the phase lugs, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not leave any debris on the mating surfaces.
  2. Inspect the gap pad of the inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the gap pad is fully attached and covering the discharge resistor array. No resistors should be visible. The gap pad should be clean of debris and evenly adhered. Replace the gap pad if it does not match the criteria.
  3. Install a new gasket to the inverter.
  4. Position the inverter with gasket to the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the rear inverter into position. Take caution when maneuvering between the subframe to avoid damage to the circuit board. Make sure the 3-phase cables and guides are aligned during installation.
  5. Hand-tighten the bolts (x12) that attach the RDU inverter to the gearcase assembly.
  6. Torque the bolts (x12) that attach the RDU inverter to the gearcase 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:
    • External Torx Plus EP10
  7. Install the bolts (x3) that attach the RDU 3-phase cable to the inverter and motor.
    11.5 Nm (8.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    If the bolts are reused, torque to 11.5 Nm. If the bolts are newly installed, torque to 12.5 Nm, reverse 180 degrees, and 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 socket
  8. Install the phase out cover onto the RDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the phase out cover or the O-rings are damaged, replace with a new unit. Lightly lubricate the cover as needed. Fully seat the cover.
  9. Install the bolts (x2) that secure the RDU phase out cover.
    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
  10. Install a new 3-phase access label (1096344-00-B).
  11. Remove the ESD wrist strap from the inverter.
  12. Install the LH mount assembly. See Rear Drive Unit Assembly - 3DU - Drive Unit - LH Mount - 3DU (Remove and Replace).
  13. Secure the cooler hose to the motor mount.
  14. Perform inverter air leak test. See Inverter Air Leak Test.
  15. With assistance, raise the drive unit and subframe into position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage the components while raising the subframe.
  16. Install the RSF brace to the rear subframe.
  17. Hand-tighten the LH and RH rear bolts that attach the subframe to the body.
  18. Install the LH and RH shear plates. See REAR SUBFRAME SHEAR PLATE- FRONT - LEFT HAND (Remove and Replace).
  19. Position the subframe to marked location.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use previous markings to align the subframe to the body. Return to original position as close as possible.
  20. Torque the LH and RH rear bolts that attach the subframe to the body.
    125 Nm (92.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolt after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21 mm socket
  21. Remove the yellow safety straps from the subframe, and then lower the rear subframe lifting tool from the vehicle.
  22. Disconnect the air supply from the subframe lifting tool, and then remove the subframe lifting tool from underneath the vehicle.
  23. Inspect the HV insulating gloves.
  24. Put on the HV insulating gloves and the leather over gloves.
  25. Install the RDU HV harness. See HV Harness - Rear Drive Unit (3DU) (Remove and Replace).
  26. Secure the RDU logic connector clip.
  27. Secure the RDU logic connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify no coolant enters into the connector.
  28. Install the clip that attaches the coolant hose to the RH shear plate.
  29. Position the coolant drain container under the LH rear of the vehicle.
  30. Install the RDU inverter inlet hose. See TUBE (PT), RDU INVERTER INLET, M3 (Remove and Replace).
  31. Install the HV battery rear skid plate. See High Voltage Battery Assembly - Skid Plate - Rear (Remove and Replace).
  32. Install the rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear - 23.6MM X 3.5MM (Remove and Replace).
  33. Install the RH side 12V subframe harness clip to the RSF brace.
  34. Install the RH side 12V subframe harness clip to the body.
  35. Install the nut that attaches the RDU ground strap to the vehicle.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  36. Install the rear fascia diffuser. See Rear Fascia - Diffuser (Remove and Replace).
  37. Install both rear wheels. See Wheel Assembly (Remove and Install).
  38. Remove the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  39. Connect the LV battery power. See LV Power (Disconnect and Connect).
  40. Unlock the vehicle gateway. See Gateway (Unlock).
  41. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  42. Tap Coolant Purge Start > Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  43. Install the 2nd row seat cushion. See 2ND ROW SEAT CUSHION (Remove and Replace).
  44. Exit Service Mode. See Service Mode.
  45. Inspect the coolant level and top off as necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at Max line.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  46. Install the coolant bottle cap.
  47. Install the HEPA filter assembly. See HEPA FILTER (Remove and Replace).
  48. Raise all windows and close all doors.
  49. Remove the vehicle from the lift.
  50. 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.