24/04/2024 20:19:31

Gearbox Fluid - Rear Drive Unit (3DU) (Drain and Refill)

Correction code 40300102 0.54 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.

  • 2024-04-05: Updated gearbox fluid information with link.
  • 2024-02-27: Updated gearbox fluid to KAF 1.
  • 2023-11-27: Added XP10 Jump Start and Oil Pump Switchbox to special tools list.
  • 2023-11-09: Updated oil pump removal steps and deleted the firmware redeploy steps.
  • 2024-04-25: Updated the description of the o-ring inspection step since the o-ring on the oil fill plug can not be replaced separately.
  • 1130484-00-A Skt, Oil Filter, 63.5mm X 14
  • 1129348-00-A Jump Start, XP-10
  • 1131264-00-A Switchbox, Oil Pump, Model 3

Drain

  1. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Open all doors and lower all windows.
  3. Note the position of the driver and front passenger seats, and then move the seats fully forward.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  6. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  7. Disconnect the electrical connector from the oil pump.
  8. Position an oil drain container underneath the rear drive unit oil filter and oil pump.
  9. Use the oil filter socket to remove the oil filter from the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tesla recommends that the oil filter is replaced with a new one upon removal. Any oil filter with visible corrosion or leaks must be replaced.
  10. Remove the bolts (x2) that attach the rear drive unit oil pump to the rear drive unit.
    Tip: Use of the following tool(s) is recommended:
    • EPL10 socket
    • 4 in extension
  11. Remove the oil pump from the rear drive unit using a flat head screwdriver at two different locations, and then allow the gearbox fluid to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the rear drive unit casting as leverage to loosen the oil pump, and then pull the oil pump away.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow at least 10 minutes for the gearbox fluid to drain from the rear drive unit, or until a slow drip exits the rear drive unit.
  12. Remove the fill plug from the rear drive unit.

Refill

  1. Inspect the seal on the oil filter, the O-ring on the fill plug, and the O-rings (x3) on the oil pump.
    • Verify there is one O-ring on the fill plug and three O-rings on the oil pump, and the oil filter seal is staying properly on the oil filter. Make sure no O-rings or seal is stuck in the rear drive unit assembly.
    • If one of the O-rings on the oil pump is damaged, replace all the three o-rings.
    • If the O-ring on the fill plug is damaged, install a new fill plug.
  2. Lubricate the oil pump O-ring (x3) with new gearbox fluid, and then reinstall the oil pump onto the rear drive unit assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
  3. Install the bolts (x2) that attach the oil pump to the rear drive unit.
    5 Nm (3.7 lbs-ft) + 20 degrees
    Tip: Use of the following tool(s) is recommended:
    • EPL10 socket
    • 4 in extension
  4. Apply a light coat of new gearbox fluid to the O-ring seal of a new oil filter, and then install the new filter onto the rear drive unit.
    3 Nm (2.2 lbs-ft) + 135 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tesla recommends that the oil filter is replaced with a new one upon removal. Any oil filter with visible corrosion or leaks must be replaced.
  5. Using the measure and fill kit, fill the container with 2300 mL of new gearbox fluid.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
  6. Connect the 12V power supply to the oil pump using the oil pump switchbox special tool and the XP-10 jump pack.
  7. Cut both the input and output hoses of the fluid transfer pump to approximately 26" (66 cm).
  8. Insert the output hose of the fluid transfer pump into the fill hole of the rear drive unit until fully seated, and then pull the output hose back 5mm.
  9. Set up the fill process by putting the container with the measured new gearbox fluid in the drain basket, and then fully submerge the input hose of the fluid transfer pump and prime the pump.
  10. With an assistant, pump the new gearbox fluid into the rear drive unit assembly as follows:
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
    Informational PurposesAn informational icon, calling your attention
    Note
    The minimum refill capacity of the rear drive unit assembly is 2.1 liters. Using excess gearbox fluid in the fill container allows the oil pump to dispense the full 2.1L without drawing air. Make sure that there is less than 200mL left when completed. Pumping the full 2.3 liters is not required.
    1. Pump 5 full strokes from the fluid container with the manual pump.
    2. Run the oil pump via the switch box for the entire fill, and then keep running the oil pump until the fill plug is installed.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not run the oil pump dry.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      If the oil pump is not running and the fill plug is not installed, the gearbox fluid will drain from the fill plug within 10 seconds.
  11. Install a new fill plug O-ring onto the fill plug, and then install the fill plug into the rear drive unit.
    15 Nm (11.1 lbs-ft)
  12. Remove the oil drain container from underneath the drive unit.
  13. Disconnect the oil pump switchbox and XP-10 jump pack from the oil pump.
  14. Connect the oil pump electrical connector, and then engage the locking tab.
    Important: Perform a push-pull test to verify that the connector is fully attached.
  15. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  16. Connect to the vehicle with Toolbox 3.0.
  17. In Toolbox, click the play button next to Oil Pump Low Pressure Test - Rear Drive UnitTEST-SELF_DIR_X_OIL-PUMP-PRESSUREGen3/tasks/TEST-SELF_DIR_X_OIL-PUMP-PRESSUREDrive Unit and select Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    This test might take up to 5 times to successfully run. If this test keeps failing, add additional fluid, if needed.
  18. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  19. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  20. Restore the driver and front passenger seat back to their original position.
  21. Remove the vehicle from the lift.