01/04/2024 13:57:09

Bushing - Rear Drive Unit - Rear (3DU) (Remove and Replace)

Correction code 40012602 3.78 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.

2024-01-11: Updated torque figure for the bolt that attaches the ground strap to the RDU from 6 Nm to 10 Nm.
2023-10-25: Updated torque figure for rear upper fore link to knuckle from 76 Nm to 84 Nm.
2023-08-23: Updated EPB Service Mode reference.
2023-06-09: Added shear plate small bolts torque figure for Structural Pack vehicles.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Open all four doors
Lower LH front window
Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
Move LH front seat forward
Move RH front seat forward
Remove 2nd row seat cushion

Note
1x connector, Lift front edge of seat cushion upward to release foam from frame
Open hood
Remove rear apron

Note
14x clips
Power off vehicle from center display

Note
Via Controls > Safety & Security > Vehicle Power > Power Off
Disconnect 12V negative terminal and first responders loop

Note
1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove the ancillary bay probe lid cover from the ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no visual damage present, Replace gasket if damage is found
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
Remove HV insulating gloves
Remove LH rear wheel cap

Note
1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
Remove RH rear wheel cap

Note
1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
Loosen RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Loosen LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle partially and lower lift onto locks

Note
Set vehicle to a comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH rear brake caliper from knuckle and hang from body

Note
2x bolts, E18, 83 Nm, Discard bolts after removal
Remove LH rear brake caliper from LH rear knuckle and hang from body

Note
2x bolts, E18, 83 Nm, Discard bolts after removal
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove mid aero shield

Note
11x bolts, 10mm, 5 Nm
Remove bolts securing rear diffuser to body

Note
9x bolts, 10mm, 4 Nm
Remove clips securing rear diffuser to body and remove from vehicle

Note
6x push clips
Remove LH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Remove RH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Install spring compressor onto LH rear coil spring

Note
Reference photos for clarification
Unbolt LH strut from body at top mount

Note
2x bolts, 15mm, 41 Nm
Install spring compressor onto RH rear coil spring
Unbolt RH strut from body at top mount

Note
2x bolts, 15mm, 41 Nm
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Disconnect RH side 12V subframe harness connector

Note
1x connector, Release locking tab
Remove RH side 12V subframe harness clip from body

Note
1x clip
Disconnect LH side 12V subframe harness connector

Note
1x connector, Release locking tab
Remove LH side 12V subframe harness clip from body

Note
1x clip
Remove nut securing RDU ground strap to vehicle

Note
1x nut, 10mm, 10 Nm
Remove nut securing LH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from LH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
Remove nut securing RH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from RH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
Position support stand to support front portion of rear subframe
Remove bolts securing stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Discard after removal
Lower support stand and remove stabilizer bar from vehicle
Remove support stand from under vehicle
Release clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Release LH side hose clip from rear battery skid plate

Note
2x clips, Clip quantity may vary on older vehicles
Release RH side hose clips from rear battery skid plate

Note
2x fir tree clips
Release clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Remove lower bolts securing rear battery enclosure skid plate

Note
2x bolts, EP10, 13 Nm
Remove upper nut securing rear battery enclosure skid plate

Note
1x nut, 10mm, 13 Nm
Remove upper bolts securing rear battery enclosure skid plate from HV battery

Note
4x bolts, 13mm, 35 Nm
Remove rear battery enclosure skid plate from HV battery pack
Position coolant drain container underneath LH rear of HV battery
Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends

Note
1x spring clip, 2x plugs
Position coolant drain container underneath LH RDU area
Disconnect RDU inverter inlet tube from fluid coupling

Note
1x spring clip, 2x plugs, Plug the hose end and the fluid coupling
Position coolant drain underneath RH rear of HV battery
Disconnect coolant outlet hose to rear PT return hose and plug hoses

Note
1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary
Remove coolant drain container from underneath vehicle
Remove nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm
Disconnect RDU HV cable from HV battery

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Place subframe lifting tool into position underneath rear subframe
Connect air supply to subframe lifting tool
Raise subframe lifting tool to support rear subframe

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
Remove smaller fasteners for LH shear plate

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard after removal
Remove smaller fasteners for RH shear plate

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard after removal
Remove LH rear bolt securing subframe to body

Note
1x bolt, 21mm, 165 Nm, Discard after removal
Remove RH rear bolt securing subframe to body

Note
1x bolt, 21mm, 165 Nm, Discard after removal
Lower subframe lifting tool to remove subframe from vehicle

Note
Use caution to not damage components while lowering subframe
Disconnect air supply from subframe lifting tool
Move the subframe lifting tool and subframe away from vehicle

Note
Raise vehicle if necessary
Remove coolant inlet hose clip from RDU

Note
1x fir tree clip
Remove coolant inlet hose from subframe
Remove bolt securing RDU HV cable bracket to RDU

Note
1x bolt, 10mm, 6 Nm
Disconnect RDU HV cable from RDU

Note
1x connector, Red locking tab
Remove RDU HV cable from subframe
Perform RDU diode test

Note
Verify RDU HV cable is disconnected from HV battery. Use a multimeter in diode mode, with the positive DMM probe to B- of the inverter and the negative probe to B+. Pin #1 on HV cables is B- and Pin #2 is B+. MOSFET acceptable diode reading:1.0 - 2.0 V. IGBT acceptable diode reading 0.45 - 2 V (if you get OL or > 2V for a reading you most likely have the probes installed the wrong way around)
Remove ground strap harness from RDU assembly
Remove LH rear wheel speed sensor from LH rear knuckle

Note
1x patch bolt, 10mm, 5 Nm
Remove grommet securing LH rear wheel speed harness to LH rear knuckle

Note
1x grommet
Remove nut and bolt securing LH rear upper aft link to LH rear knuckle

Note
1x bolt, 1x nut, 21mm, 134 Nm
Remove nut and bolt securing LH rear upper fore link to LH rear knuckle

Note
1x bolt, 1x nut, 18mm, 84 Nm
Remove nut and bolt securing LH rear toe link to LH rear knuckle

Note
1x bolt, 1x nut, 18mm, 76 Nm
Disconnect RDU 12V connector

Note
1x connector
Remove RDU 12V harness clip

Note
1x clip
Disconnect resolver connector from rear drive unit

Note
1x connector, 2x clips
Disconnect oil pump connector

Note
1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
Remove RH rear wheel speed sensor from RH rear knuckle

Note
1x patch bolt, 10mm, 5 Nm
Remove grommet securing RH rear wheel speed sensor to RH rear knuckle

Note
1x grommet
Remove nut and bolt securing RH rear upper aft link to RH rear knuckle

Note
1x bolt, 1x nut, 21mm, 134 Nm
Remove nut and bolt securing RH rear upper fore link to RH rear knuckle

Note
1x bolt, 1x nut, 18mm, 84 Nm
Remove nut and bolt securing RH rear toe link to RH rear knuckle

Note
1x bolt, 1x nut, 18mm, 76 Nm
Release LH halfshaft from rear drive unit

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
Remove LH halfshaft from rear drive unit

Note
Recommend assistance, Install axle seal plug
Release RH halfshaft from rear drive unit

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
Remove RH halfshaft from rear drive unit

Note
Recommend assistance, Install axle seal plug
Position drive unit stand underneath gantry
Attach drive unit sling tool to drive unit

Note
3x hooks
Secure drive unit sling to gantry
Raise sling so there is slight tension on the cables
Remove LH bolt securing drive unit to subframe

Note
1x bolt, 18mm, 80 Nm
Remove RH bolt securing drive unit to subframe

Note
1x bolt, 18mm, 80 Nm
Remove bolt securing rear of drive unit to subframe

Note
1x bolt, 18mm, 80 Nm
Raise sling to lift drive unit out of subframe

Note
Recommend assistance, Carefully guide halfshafts away from FDU while lifting
Move subframe and lifting tool from underneath drive unit
Position empty drive unit crate below drive unit

Note
Use pallet if no empty crate available
Lower drive unit into drive unit crate

Note
Use pallet if no empty crate available
Lower sling to release tension on the cables
Remove drive unit sling from gantry
Remove drive unit sling tool from drive unit
Attach RDU engine stand adapter to RDU

Note
3x bolts, 15mm, 3x nuts, 15mm, Hand tight, Recommend assistance
Attach gantry hook to RDU adapter
Using gantry, lift RDU assembly for installation onto engine stand
Move engine stand into position
Install RDU adapter to engine stand

Note
4x bolts, 18mm, 4x nuts 18mm
Install bushing removal tool on gearcase bushing

Note
2x nuts, 22mm, Use cups "C", "A", and "G" to drive bushing out, Always drive on the bearing side and hold the opposite
Press gearcase bushing out from casting
Separate bushing tool and remove gearcase bushing
Setup tool to press in new gearcase bushing

Note
2x nuts, 22mm, Use cups "D" and "E" to install bushing, Always drive on the bearing side and hold the opposite, Ensure the keyway is up and the lug on the bushing is in the center of the "D" cup opening
Press in new gearcase bushing

Note
Apply spray lubricant to the bushing exterior before install
Separate bushing tool and remove from drive unit
Using the gantry hook, support the RDU engine stand adapter, applying tension
Remove the bolts securing RDU engine stand adapter to engine stand and move engine stand away

Note
4x bolts, 18mm, 4x nuts, 18mm
Lower RDU and engine stand adapter onto crate
Remove gantry hook from RDU adapter and move aside
Remove RDU engine stand adapter from RDU

Note
3x bolts, 15mm, 3x nuts, 15mm
Attach drive unit sling tool to drive unit

Note
3x hooks
Secure drive unit sling to gantry
Raise drive unit out of drive unit crate
Move subframe and lifting tool underneath drive unit
Lower sling to install rear drive unit into subframe

Note
Recommend assistance, Carefully guide halfshafts away from FDU while lowering
Install rear bolt securing drive unit to subframe, hand tight

Note
1x bolt, 18mm, 80 Nm, Torque at a later step
Install RH bolt securing drive unit to subframe, hand tight

Note
1x bolt, 18mm, 80 Nm, Torque at a later step
Lower sling to release tension on the cables
Remove drive unit sling from gantry
Remove drive unit sling tool from drive unit

Note
3x hooks
Torque motor mount bolts

Note
3x bolts, 18mm, 80 Nm
Install LH halfshaft to drive unit

Note
Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
Install RH halfshaft to drive unit

Note
Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
Secure clips holding coolant outlet hose to drive unit

Note
4x clips
Secure coolant outlet hose to drive unit cooler

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Secure inverter to cooler hose to cooler

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Secure clips holding inverter to coolant hose to RDU

Note
4x clips
Secure inverter to cooler hose to inverter

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Connect resolver connector to drive unit

Note
1x connector, 2x clips, Engage locking tab
Connect oil pump connector

Note
1x connector, Engage locking tab
Install RH rear toe link to knuckle and hand tighten nut and bolt

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
Install RH rear upper fore link to knuckle and hand tighten nut and bolt

Note
1x bolt, 1x nut, 18mm, 84 Nm, Recommend assistance, Torque at later step
Install RH upper aft link to knuckle and hand tighten nut and bolt

Note
1x bolt, 1x nut, 21mm, 134 Nm, Recommend assistance
Loosely install RH rear lower fore link to RH rear knuckle

Note
1x nut, 18mm, 76 Nm, Torque at later step
Install grommet securing RH wheel speed sensor to knuckle

Note
1x grommet
Install bolt securing RH wheel speed sensor to knuckle

Note
1x patch bolt, 10mm, 5 Nm
Install RDU 12V harness clip

Note
1x clip
Install RDU 12V connector

Note
1x connector
Install the bolt that attaches the ground strap harness to the RDU assembly .
10 Nm (7.4 lbs-ft)
Install LH rear toe link to knuckle and hand tighten nut and bolt

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
Install the nut and bolt that attach the LH rear upper fore link to the knuckle.

Note
1x bolt, 1x nut, 18mm, 84 Nm, Torque at later step
Install LH rear upper aft link to LH rear knuckle and hand tighten nut and bolt

Note
1x bolt, 1x nut, 21mm, 134 Nm
Loosely install LH rear lower fore link to LH rear knuckle

Note
1x bolt, 1x nut, 18mm, 76 Nm, Torque at later step
Install grommet securing LH rear wheel speed sensor harness to LH rear knuckle

Note
1x grommet
Install LH rear wheel speed sensor to LH rear knuckle

Note
1x patch bolt, 10mm, 5 Nm
Install RDU HV cable into position on the rear subframe
Connect RDU HV cable to RDU

Note
1x connector, Install HV connector lever lock to RDU HV cable connector, Align connector to RDU then remove HV connector lever lock before fully latching 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
Install bolt securing RDU HV cable bracket to RDU

Note
1x bolt, 10mm, 6 Nm
Install coolant inlet hose into subframe
Remove hose plugs and connect coolant inlet hose to rear drive unit

Note
1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
Install coolant inlet hose clip to RDU

Note
1x fir tree clip
Position subframe lifting tool and subframe under vehicle
Connect air supply to subframe lifting tool
Raise drive unit and subframe into position

Note
Use caution to not damage components while raising subframe
Install RH rear bolt securing rear subframe to body hand tight

Note
1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
Install LH rear bolt securing rear subframe to body hand tight

Note
1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
Install bolt and shear plate to LH side of rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
Install bolts securing LH rear shear plate to body hand tight

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
Install bolt and shear plate to RH side of rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
Torque bolts securing shear plates to vehicle

Note
4x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
Torque bolt securing subframe and LH rear shear plate to body

Note
1x bolt, 21mm, 130 Nm
Torque bolt securing subframe and RH rear shear plate to body

Note
1x front bolt, 21mm, 130 Nm
Torque bolt securing RH rear of subframe to body

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
Torque bolt securing LH rear of subframe to body

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
Install clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Install clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Lower rear subframe lifting tool from vehicle

Note
Verify yellow safety straps are removed from subframe
Disconnect air supply from subframe lifting tool
Remove subframe lifting tool from underneath vehicle
Connect RDU HV cable to HV battery

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
Install nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm
Position coolant drain underneath RH rear of HV battery
Remove hose plugs and connect coolant outlet hose to rear PT return hose

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary
Position coolant drain container underneath LH rear of HV battery
Remove plugs and connect RDU inverter inlet hose to rear of HV battery

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Remove coolant drain container from underneath vehicle
Position rear battery enclosure skid plate to HV battery for installation
Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight

Note
4x bolts, 13mm, 35 Nm, Torque at later step
Install upper nut securing rear battery enclosure skid plate hand tight

Note
1x nut, 10mm, 13 Nm, Torque at later step
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
Torque bolts securing HV battery and rear skid plate to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque upper nut securing rear battery enclosure skid plate

Note
1x nut, 10mm, 13 Nm
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
Install RH side hose clips to rear battery skid plate

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
Place stabilizer bar into position for installation and raise stand to support stabilizer bar
Install bolts securing stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Install new patch bolts
Position LH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing LH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
Position RH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing RH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
Remove support stand from under vehicle
Install the RDU ground strap to body

Note
1x bolt, 10mm, 10 Nm
Install LH side 12V subframe harness clip to body

Note
1x clip
Connect LH side 12V subframe harness connector

Note
1x connector, Engage locking tab
Install RH side 12V subframe harness clip to body

Note
1x clip
Connect RH side 12V subframe harness connector

Note
1x connector, Engage locking tab
Install rear diffuser to rear fascia assembly and secure clips to body

Note
6x clips
Apply Loctite 222 onto rear diffuser bolts and install bolts securing rear diffuser to body

Note
9x bolts, 10mm, 4 Nm
Lower vehicle partially and set onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Install bolts securing RH damper to body at top mount

Note
2x bolts, 15mm, 41 Nm
Install RH rear brake caliper onto knuckle

Note
2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
Remove bolt securing RH rotor to hub

Note
1x bolt, 10mm, 5 Nm
Install hub jack adapter onto RH rear hub

Note
5x lug nuts, 21mm, Hand tight
Position and raise support stand to simulate RH rear suspension at ride height
Use rear ride height torque gauge to verify RH suspension is set to ride height specification

Note
May need to slightly adjust stand or compression tool
Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height

Note
Distance should be 427 mm
Torque bolt securing RH rear toe link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque the bolt that attaches the RH rear upper fore link to the knuckle.
84 Nm (61.9 lbs-ft)

Note
1x bolt, 18mm, 84 Nm, Mark with paint pen
Torque bolt securing RH rear lower fore link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing RH rear upper aft link to knuckle

Note
1x bolt, 21mm, 134 Nm, Mark with paint pen
Remove support stand from underneath RH suspension
Remove hub jack adapter from RH rear hub

Note
5x lug nuts, 21mm, Hand tight
Install bolt securing RH rotor to hub

Note
1x bolt, 10mm, 5 Nm
Remove spring compressor from RH rear coil spring
Install bolts securing LH damper to body at top mount

Note
2x bolts, 15mm, 41 Nm, Apply pressure at top of damper to push down and clear wheel liner
Install LH rear brake caliper onto LH rear knuckle

Note
2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
Remove bolt securing LH rotor to hub

Note
1x bolt, 10mm, 5 Nm
Install hub jack adapter onto LH rear hub

Note
5x lug nuts, 21mm, Hand tight
Position and raise support stand to simulate LH rear suspension at ride height
Use rear ride height torque gauge to verify LH suspension is set to ride height specification

Note
May need to slightly adjust stand or spring compressor tool
Measure from bottom of quarter panel to center of axle as a secondary check to make sure LH suspension is set to ride height

Note
Distance should be 427 mm
Torque bolt securing LH rear toe link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque the bolt that attaches the LH rear upper fore link to the knuckle.
84 Nm (61.9 lbs-ft)
Torque bolt securing LH rear lower fore link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing LH rear upper aft link to knuckle

Note
1x bolt, 21mm, 134 Nm, Mark with paint pen
Remove support stand from underneath LH rear suspension
Remove hub jack adapter from LH rear hub

Note
5x lug nuts, 21mm, Hand tight
Install bolt securing LH rear rotor to LH rear hub

Note
1x bolt, 10mm, 5 Nm
Remove spring compressor from LH rear coil spring
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Install LH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Install RH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note
9x bolts, 10mm, 5 Nm
Lower vehicle partially and set onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Install LH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Install RH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install LH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Remove coolant bottle cap
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Connect first responder loop and 12V negative terminal

Note
1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
Install 2nd row seat cushion

Note
1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
Move RH front seat to original position
Move LH front seat to original position
Press and hold park button to release EPB service mode

Note
Remove wheel chocks if necessary
Connect to vehicle using Toolbox 3.0
Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
Select ‘Coolant Air PurgeTEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEGen3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE Model3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGELow Voltage Controllers Low Voltage ControllersThermal / Actions - Coolant Air PurgeService Mode Service Plus Factory Mode Developer Thermal / Coolant System - Coolant Air PurgeService Mode Service Plus Factory Mode Developer hv / Procedures - Transport Service Plus Developer ’, click ‘Run’, and allow routine to complete

Note
Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Install coolant bottle cap
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Raise all four windows
Close all four doors

Note
If 12V is powered up, Unlatch rear doors before closing
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
Check tire pressures

Note
4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar
Verify the alignment slip/turn plates are locked
Drive vehicle onto alignment rack
Pull vehicle forward and stop ~ 0.5 ft before turn plates to allow for rolling compensation

Note
Shift to park
Shift to park
Install wheel chocks

Note
Place chocks on both sides of the driver's side rear tire
Latch the driver seat belt to buckle
Latch LH front door and place vehicle into neutral

Note
Careful not to slam the door while latch is engaged
Raise alignment rack partially and lower to lock position
Install alignment heads onto wheels

Note
4x alignment heads
Enter vehicle information to alignment machine
Perform rolling compensation

Note
Remove the wheel chocks from the LH rear tire and push the back of the tire to roll vehicle forward. Reinstall wheel chocks once vehicle is in position
Unlock alignment slip/turn plates
Verify chassis height measurement tool is calibrated

Note
Adjust if necessary, Measure height of tool and adjust reading to match
Perform ride height measurement

Note
Measure the ride height 75mm inward of the HV battery ski hole at each corner, If using ballast bags, move the front seats as necessary to achieve ride height spec, See Service Manual for ride height specifications
Apply brake pedal depressor
Perform caster sweep and install steering wheel holder and level tool

Note
If camber and caster are out of specification, perform necessary camber and caster adjustment
Verify alignment reading is within specification and print vehicle summary
Remove alignment heads from wheels

Note
4x alignment heads
Remove brake pedal depressor
Lock alignment slip/turn plates
Lower the alignment rack to ground
Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
Unlatch LH front seat belt
Remove wheel chocks
Remove vehicle from alignment rack
Perform test drive

Note
Per current FRT (00040100) 0.3 hrs, If alignment was adjusted verify tracking, If DAS components were adjusted verify operation, If brakes were serviced perform burnishing