22/05/2024 15:23:56

Inverter - Front Drive Unit (Remove and Replace)

Correction code 39200602 3.90 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.
  • 2023-07-25: Removed resolver error learn substeps.
  • 1076971-02-A - WRENCH, TORQUE+ANGLE, 1/4" DR

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 Post Lift.
  3. Place stanchions around the rear of the vehicle to setup a safety perimeter.
  4. Verify that the vehicle firmware is version 2022.20.6 or later. Update the vehicle firmware if this is not the case. See Software Update.
  5. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  6. In Toolbox 3, click the Dashboards tab, and type ‘Front Drive Inverter Replacement' into the search field.
  7. Click FRONT Drive INVERTER - Replacement, from the BEFORE INVERTER SWAP Action List, click Store Drive Inverter Slave Bootloader Data before Replacement, click Run, and then allow the routine to complete.
  8. From the BEFORE INVERTER SWAP Action List, click Store Drive Inverter Slave Application Data before Replacement, click Run, and then allow the routine to complete.
  9. From the BEFORE INVERTER SWAP Action List, click Start Thermal Fluid Fill/Drain (Coolant only), click Run, and then allow the routine to complete.
  10. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not close this instance of Toolbox 3 as it is needed later on in the procedure.
  11. Use a steering wheel lock to firmly set the steering wheel in the straight forward position.
  12. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  13. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  14. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  15. Remove the bolt that attaches the intermediate shaft to the steering gear, and then slide the intermediate shaft upwards to remove it from the steering gear.
    Figure 1.
  16. Slide the red tab to unlock, press the connector release, and then disconnect the electrical harness from the steering gear power connectors (x2).
  17. Remove the front LH and RH fender garnishes. Garnish - Fender - Front - LH (Remove and Replace).
  18. Remove the front LH and RH wheels. See Wheel Assembly (Remove and Install).
  19. Remove the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  20. Remove the front fascia. See Fascia - Front (Remove and Install).
  21. Remove the front subframe. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
  22. Move a coolant catcher under the front subframe and fixture assembly.
  23. Release the clip, disconnect the front drive unit inverter to heat exchanger hose from the front drive unit inverter outlet, plug the inverter fitting, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel to direct flow.
    Figure 2.
  24. Release the clip, disconnect the front drive unit inverter to heat exchanger hose from the front drive unit heat exchanger, plug the heat exchanger fitting, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel to direct flow.
    Figure 3.
  25. Release the clips (x2) that attach the front drive unit inverter to heat exchanger hose to the front drive unit, and then remove the hose from the front drive unit.
    Figure 4.
  26. Release the clip, disconnect the front drive unit inverter inlet hose from the front drive unit inverter inlet, plug the inverter fitting, and then allow the hose to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel to direct flow.
  27. Release the clips (x2) that attach the front drive unit inverter inlet hose to the front drive unit, and then remove the hose from the drive unit.
  28. Release the locking tab, push the handle downward, and then disconnect the subframe electrical harness from the front drive unit inverter logic connector.
  29. Release the clips (x2) that attach the subframe electrical harness to the inverter.
  30. Remove the bolts (x3) that attach the LH motor mount to the front drive unit, and then remove the mount from the drive unit.
  31. Attach an Electrostatic Discharge (ESD) wrist strap to the front drive unit inverter housing.
  32. Remove and discard the front drive unit phase out cover label.
  33. Remove the bolts (x2) that attach the phase out cover to the front drive unit gearbox, and then use a plastic trim tool to remove the cover from the gearbox.
  34. Inspect the condition of the phase out cover and O-rings. If the cover has less than 6 O-rings, or if the O-rings or cover are damaged, discard the cover and use a new cover, part 1096984-00-C or newer revision, for installation.
  35. Remove the bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals.
  36. Remove the bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox.
  37. Carefully remove the inverter assembly from the front drive unit, remove the plugs, and allow the coolant to drain.
  38. Place the removed front drive unit inverter onto an ESD mat, and then remove the ESD wrist strap from the inverter.
  39. Inspect the front drive unit gearbox housing to make sure that there is no gap pad stuck there. If there is, remove the gap pad, clean the area with an alcohol wipe, and allow at least one minute to dry.

Install

  1. Secure ESD strap to new inverter housing
  2. Inspect the condition of the gap pad on the inverter PCB. Replace the gap pad if it does not fulfill these criteria:
    • New and undamaged condition.
    • Fully covers the discharge resistor array and no resistors are visible.
    • Clean and free of debris.
    • Evenly adhered to the inverter PCB.
  3. Use an IPA wipe to clean the HV mating surfaces of the front drive unit motor and front drive unit inverter 3-phase terminals.
  4. Install a new front drive unit inverter gasket onto the inverter.
  5. Carefully align the front drive unit inverter to the 2 pins in the front drive unit, and then install the inverter onto the drive unit. Make sure that the 3-phase terminals align during installation.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid damage to the printed circuit board of the inverter.
  6. Install and hand-tighten the bolts (x12) that attach the front drive unit inverter to the front drive unit gearbox.
  7. Torque the bolts (x12) in the sequence shown.
    12.5 Nm (9.2 lbs-ft)
  8. Install and hand-tighten the bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals.
  9. Tighten the bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals.
    11.5 Nm (8.5 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If any bolts are dropped into the gearbox housing, they must be retrieved.
    Informational PurposesAn informational icon, calling your attention
    Note
    If installing a new bolt, tighten to 12.5 Nm, back off 180 degrees, then torque to 5 Nm +40 degrees.
  10. Lightly lubricate the front drive unit gearbox phase out cover bores with clean gearbox fluid, and if a new phase out cover is to be installed, lightly lubricate the O-rings of the cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Fluids and Capacities to determine which gearbox fluid is applicable.
  11. Install the phase out cover into the front drive unit gearbox, and then install the bolts (x2) that attach the cover to the gearbox.
    14 Nm (10.3 lbs-ft)
  12. Apply a new front drive unit inverter phase out cover label.
  13. Attach the ESD wrist strap to the old inverter, place the old inverter into the ESD return box, and then remove the ESD wrist strap from the old inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Replace the service plugs with the factory shipping plugs from the new inverter.
  14. Perform an inverter air leak test. See Inverter Air Leak Test.
  15. Install the LH motor mount to the front drive unit, and then install and hand-tighten the bolts (x3) that attach the mount to the drive unit.
  16. Torque the bolts (x3) in the sequence shown.
    35 Nm (25.8 lbs-ft) +55 deg
  17. Fasten the clips (x2) that attach the subframe electrical harness to the front drive unit inverter.
  18. Connect the subframe electrical harness to the front drive unit inverter logic connector, raise the handle upward, and then fasten the locking tab.
  19. Install the front drive unit inverter inlet hose to the front drive unit, and then fasten the clips (x2) that attach the hose to the drive unit.
  20. Connect the front drive unit inverter inlet hose to the front drive unit inverter inlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  21. Install the front drive unit inverter to heat exchanger hose to the front drive unit, and then fasten the clips (x2) that attach the hose to the drive unit.
    Figure 5.
  22. Connect the front drive unit inverter to heat exchanger hose to the front drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
    Figure 6.
  23. Connect the front drive unit inverter to heat exchanger hose to the front drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
    Figure 7.
  24. Install the front subframe. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
  25. Install the front fascia. See Fascia - Front (Remove and Install).
  26. Install the front LH and RH fender garnishes. Garnish - Fender - Front - LH (Remove and Replace).
  27. Install the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  28. Connect the electrical harness to the steering gear power connectors (x2), and then slide the red tab to lock the connectors.
  29. Slide the intermediate shaft down onto the steering gear, and then install the bolt that attaches the intermediate shaft to the steering gear.
    18 Nm (13.3 lbs-ft)
    Figure 8.
  30. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  31. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  32. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  33. Remove the steering wheel lock from the steering wheel.
  34. Connect the laptop with Toolbox 3.
  35. From the AFTER INVERTER SWAP Action List, click Stop Thermal Fluid Fill/Drain, click Run, click Submit, and then allow the routine to complete.
  36. From the AFTER INVERTER SWAP Action List, click Restore FRONT Drive INVERTER Bootloader Data after Replacement and Usage ID Configuration, click Run, and then allow the routine to complete.
  37. From the AFTER INVERTER SWAP Action List, click Service CAN Redeploy, click Run, and then allow the routine to complete.
  38. From the AFTER INVERTER SWAP Action List, click Restore Drive Inverter Slave Application Data after Replacement, click Run, click Submit, and then allow the routine to complete.
  39. From the AFTER INVERTER SWAP Action List, click Coolant Air Purge, click RUN, and then allow the routine to complete.
  40. From the AFTER INVERTER SWAP Action List, click Thermal System Performance Test, click Run, and then allow the routine to complete.
  41. Inspect the coolant level and top up if necessary. See Cooling System (Partial Refill and Bleed).
  42. Manually engage the hood latch.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the hood is open, or if the hood latch is not manually engaged, the vehicle speed will be limited and the resolver learn routine will fail.
  43. Touch the brake pedal to ensure the drive rails are on, and then click NEXT.
  44. From the RESOLVER LEARN Action List, click Inverter Resolver Error Learning, click Run, and follow the displayed instructions.
  45. Disconnect the laptop with Toolbox 3 from the vehicle.
  46. Install the front LH and RH wheels. See Wheel Assembly (Remove and Install).
  47. Remove the stanchions from the rear of the vehicle.
  48. On the vehicle touchscreen, open the hood to disengage the hood latch.
  49. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  50. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  51. Perform a validation test drive at road and highway speeds to determine if an alignment check is necessary.
    • If the test drive shows the vehicle to track poorly or pull to the side, or if steering is sloppy or off center, then perform a four wheel alignment check. See Four Wheel Alignment Check, and add this service to the SV.
    • If the test drive shows the vehicle to steer and handle as expected, then an alignment check is not necessary.