06/11/2024 04:23:02

Subframe Assembly - Front (Dual Motor) (Remove and Replace)

Correction code 30010312 4.20 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.

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.

Remove

Raise and support vehicle

Note
Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
Open all four doors and lower all windows
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT
via 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
Note
Select "X" at top right of window to close once complete, For AC related repairs verify all EXV's are in proper position, For all coolant related repairs verify vehicle is in Series, Thermal Fluid Fill/Drain routine has a 5 hour timeout, Routine will continuously run and not end
Move LH front seat forward
Move RH front seat forward
Release 2nd row seat cushion

Note
Lift front edge of seat cushion upward to release foam from frame, Pull towards front of vehicle then tilt bench against 40/60 back
Move LH front seat backward
Set steering wheel straight ahead
Lock steering wheel into position
Open hood
Remove rear apron

Note
14x clips
Remove access panel

Note
3x clips, 1x connector
Remove fasteners securing the frunk assembly

Note
5x bolts, 10mm, 5 Nm
Remove frunk assembly from vehicle

Note
4x clips, Replace any clips if broken or missing
Remove fasteners holding upper portion of front fascia to vehicle

Note
5x bolts, 10mm, 4 Nm
Remove bolt securing the steering gear assembly to intermediate shaft assembly

Note
1x bolt, 13mm, 18 Nm
Slide the electric steering column upward to remove it from the steering gear assembly
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
Disconnect the steering gear assembly connectors

Note
2x connectors, Two stage connectors, Slide red locking tab to unlock, then depress the connector release to disconnect
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, E10 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
Position the ancillary bay probe lid cover to the ancillary bay cover

Note
Inspect gasket to confirm it has no visual damage
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new rubber washer bolts
Remove HV insulating gloves
Remove LH front 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 front 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 front wheel

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

Note
5x nuts, 21mm, 175 Nm
Loosen LH front halfshaft nut

Note
1x nut, 32mm, 245 Nm
Loosen RH front halfshaft nut

Note
1x nut, 32mm, 245 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
Remove outer fasteners from front aero shield

Note
7x bolts, 10mm, 5 Nm
Remove remaining nuts and remove front aero shield from vehicle

Note
2x nuts, 15mm, 5 Nm
Release LH front wheel liner from HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Release RH front wheel liner from HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
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
Remove LH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove LH front halfshaft nut and washers

Note
1x nut, 32mm, 245 Nm, The washers are attached to the nut, Discard after removal
Remove LH front fender garnish

Note
11x clips, 1x push clip, 3x tabs, Release front clip first and work around to the end of the garnish
Remove bolt securing LH side of fascia to fender

Note
1x bolt, 10mm, 4 Nm
Remove clips securing LH front wheel liner to vehicle

Note
14x clips
Remove LH front wheel liner from vehicle
Remove bolt securing LH front wheel speed sensor to knuckle

Note
1x bolt, 10mm, 5 Nm, Discard fastener after removal
Remove LH front wheel speed sensor harness from knuckle and move aside

Note
2x harness clips
Remove nut securing the LH tie rod end to the knuckle

Note
1x nyloc nut, 22mm, 180 Nm, Discard after removal
Remove LH tie rod end from knuckle
Remove RH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH front halfshaft nut and washers

Note
1x nut, 32mm, 245 Nm, The washers are attached to the nut, Discard after removal
Remove RH front fender garnish

Note
11x clips,1x push clip, 3x tabs, Release front clip first and work around to the end of the garnish
Remove bolt securing RH side of fascia to fender

Note
1x bolt, 10mm, 4 Nm
Remove clips securing RH front wheel liner to vehicle

Note
14x clips
Remove RH front wheel liner from vehicle
Remove bolt securing RH front wheel speed sensor to knuckle

Note
1x bolt, 10mm, 5 Nm
Remove RH front wheel speed sensor harness from knuckle and move aside

Note
2x harness clips
Remove nut securing the RH tie rod end to the knuckle

Note
1x nyloc nut, 22mm, 180 Nm, Discard after removal
Remove RH tie rod end from knuckle
Disconnect 12V harness for front fascia

Note
1x locking connector, Release the locking tab by sliding it away from the connector, Then depress the grey lock to release the connector
Release pedestrian warning harness

Note
1x connector, 1x clip, Pull tab to disengage lock, Pull again release from connector, Speaker is located behind RH wheel liner
Release both front corners then release front of front fascia by pulling upward and away from vehicle and place onto padded surface

Note
8x clips, Recommend assistance, Use caution not to damage headlamp or fender during removal
Remove bolts securing front end carrier to LH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Remove bolts securing front end carrier to RH front subframe crash can assembly

Note
2x bolts, 13mm, 16 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
Remove nut securing front stabar link to LH front stabar

Note
1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
Move LH front stabar link assembly aside

Note
May need to move the stabilizer bar up/down to get the correct angle needed to remove end link
Remove nut securing front stabar to RH front stabar link assembly

Note
1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
Move RH front stabar link assembly aside

Note
May be necessary to pull down on the sway bar to allow the end link to disengage
Remove bolt and nut securing LH front lower comp link to front subframe

Note
1x bolt, 21mm, 1x nut, 21mm, 115 Nm
Move the LH front lower comp link aside
Remove bolts securing LH front lower lateral link to front subframe

Note
2x bolts, 21mm, 115 Nm
Remove bolt and nut securing LH strut to LH front lower lateral link

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Remove bolt and nut securing RH front lower comp link to front subframe

Note
1x bolt, 21mm, 1x nut, 21mm, 115 Nm
Move the RH front lower comp link aside
Remove bolts securing RH front lower lateral link to front subframe

Note
2x bolts, 21mm, 115 Nm
Remove bolt and nut securing RH strut to lower control arm and move the RH front lower lateral link aside

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Loosen the bolts securing front subframe to LH front subframe crash can assembly

Note
2x bolts, 15mm, 53 Nm, This will help when installing the subframe
Loosen the bolts securing front subframe to RH front subframe crash can assembly

Note
2x bolts, 15mm, 53 Nm, This will help when installing the subframe
Position coolant drain container underneath RH front of HV battery
Disconnect FDU coolant inlet hose at RH front of HV battery and plug both hose ends

Note
1x spring clip
Place coolant drain container below RH side of FDU
Disconnect coolant hose from the FDU oil cooler to the coolant bottle and allow coolant to drain

Note
1x spring clip
Install plugs to both open coolant hose connections

Note
1x spring clip
Position coolant drain container below LH side of radiator
Disconnect FDU coolant inlet hose at LH side of radiator and plug both ends

Note
1x spring clip
Remove coolant drain container from underneath vehicle
Disconnect connectors from horn assembly

Note
2x connectors
Disconnect the logic connectors below steering gear

Note
2x connectors, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector, Image zoomed out for location reference
Release harness clip from subframe assembly

Note
1x clip, Image zoomed out for location reference
Release harness clip from lower clip

Note
1x clip
Disconnect harness from LH front rail bracket

Note
1x connector, Red locking tab, Release lock from opposite side of bracket then release connector towards front of vehicle, Image zoomed in for clarity
Remove bolt securing FDU HV harness to the FDU

Note
1x bolt, 10mm, 10 Nm
Disconnect the FDU HV harness connector

Note
1x clip, 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 FDU header are not damaged
Remove the FDU HV harness connector from the FDU and move aside

Note
1x connector
Remove bolt securing FDU ground strap to FDU

Note
1x bolt, 10mm, 6 Nm
Remove FDU ground strap harness clip from FDU

Note
1x clip
Loosen bolt securing FDU ground strap to HV battery and move aside

Note
1x bolt, 10mm, 10 Nm
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 hydraulic hub puller onto LH wheel studs

Note
5x nuts, 21mm, Hand tight
Separate the LH axle from the hub assembly and move axle aside

Note
Turn the screw clockwise to separate the axle from the hub, Counter hold so the tool and hub does not free spin
Remove the hydraulic hub puller from the LH wheel studs

Note
5x nuts, 21mm, Hand tight
Install hydraulic hub puller onto RH wheel studs

Note
5x nuts, 21mm, Hand tight
Separate the axle from the hub assembly and move axle aside

Note
Turn the screw clockwise to separate the axle from the hub, Counter hold so the tool and hub does not free spin
Remove the hydraulic hub puller from the RH wheel studs

Note
5x nuts, 21mm, Hand tight
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
Move the subframe lifting tool underneath the front subframe area
Connect air supply to subframe lifting tool
Position and support the front subframe with subframe lifting tool

Note
Recommend assistance, Latch the subframe to subframe lifting tool, Make sure to align the two guides
Position the rear FDU support posts to the FDU

Note
Both FDU supports need to engage the FDU, The left side post is dimpled and fits into a recess on the FDU and the right side post has a teflon block that sits against the FDU, Both posts are threaded and the handle should be turned until the posts are tight
Remove bolt securing the LH motor mount to the LH motor mount bracket

Note
1x bolt, E18, 105 Nm
Remove bolt securing the RH motor mount to the RH motor mount bracket

Note
1x bolt, E18, 105 Nm
Remove bolt securing LH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove bolt securing RH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove LH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm, Discard after removal
Remove RH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm, Discard after removal
Remove LH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove RH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove LH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm, Discard after removal
Remove RH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm, Discard after removal
Lower the subframe from vehicle

Note
Recommend assistance
Disconnect air supply from subframe lifting tool
Remove subframe lifting tool from under vehicle
Remove outer bolts securing steering gear assembly to front subframe

Note
2x bolts, 15mm, 27 Nm
Remove inner bolts securing steering gear assembly to front subframe

Note
2x bolts, 18mm, 75 Nm
Remove the steering gear assembly from front subframe
Remove the LH front axle shaft from the FDU

Note
1x axle, Position cable around axle and use slide hammer to release from DU
Remove the RH front axle shaft from the FDU

Note
1x axle, Position cable around axle and use slide hammer to release from DU
Disconnect the FDU inverter logic connector

Note
1x connector, Release locking tab then push the handle downward to release connector
Remove the FDU harness clips from the inverter

Note
2x clips
Remove FDU harness clips from LH side of front subframe

Note
3x clips
Remove FDU harness clips in front of front subframe

Note
2x clips
Remove FDU harness clips from RH side of front subframe

Note
3x clips
Remove the FDU harness clip from the motor

Note
1x clip
Disconnect the resolver logic connector

Note
1x connector, Release red locking tab, Press down on locking tab then release connector
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 FDU harness from front subframe
Remove LH nuts securing front stabar to front subframe

Note
2x nyloc nuts, 15mm, 35 Nm, Discard after removal, Recommend assistance
Remove RH nuts securing front stabar to front subframe and remove from vehicle

Note
2x nyloc nuts, 15mm, 35 Nm, Discard after removal, Recommend assistance
Remove bolts securing front subframe to LH front subframe crash can assembly

Note
2x bolts, 15mm, 53 Nm
Remove bolts securing front subframe to RH front subframe crash can assembly

Note
2x bolts, 15mm, 53 Nm
Remove bolt securing horn assembly to front subframe

Note
1x bolt, 10mm, 12 Nm
Release clip securing inverter hose to subframe

Note
1x clip
Position the front subframe assembly under gantry
Install the drive unit sling onto the gantry hook
Install the drive unit sling onto the FDU

Note
3x FDU connections
Raise gantry hook to put tension onto the sling
Remove the front FDU mount bolt

Note
1x bolt, 18mm, 80 Nm
Lift the FDU up and away from the front subframe

Note
Ensure the rear FDU support posts are not moved out of their current position
Remove the straps securing the front subframe to the subframe jig

Note
3x straps
Remove the front subframe from subframe lifting tool

Note
Recommend assistance

Install

Position the front subframe to subframe lifting tool

Note
Recommend assistance, Make sure the 2x guides align
Install straps securing the front subframe to subframe lifting tool

Note
3x straps
Lower the FDU into the front subframe

Note
Ensure the rear FDU support posts are in the same location when the FDU was lifted
Install the FDU mount bolt

Note
1x bolt, 18mm, 80 Nm, May need to adjust gantry to ease install
Lower gantry hook to relieve tension on the drive unit sling
Remove the drive unit sling from the FDU

Note
3x FDU connections
Remove the drive unit sling from the gantry hook
Remove the front subframe assembly from the gantry area

Note
Return subframe and lifting tool to the vehicle work area
Secure inverter hose to subframe

Note
1x clip
Install FDU harness to front subframe
Install the FDU harness clip to the motor

Note
1x clip
Connect the resolver logic connector

Note
1x connector, Engage locking tab
Connect the oil pump connector

Note
1x connector, Install locking tab after the connector is fully seated, Perform push-pull test after locking tab is seated
Install FDU harness clips to RH side of front subframe

Note
3x clips
Install FDU harness clips to front of front subframe

Note
2x clips
Install FDU harness clips to LH side of front subframe

Note
3x clips
Install the FDU harness clips to the inverter

Note
2x clips
Connect the FDU inverter logic connector

Note
1x connector, Engage locking tab
Install bolt securing horn assembly to front subframe

Note
1x bolt, 10mm, 12 Nm
Loosely install the bolts securing LH front subframe crash can assembly to front subframe

Note
2x bolts, 15mm, 53 Nm
Loosely install the bolts securing front subframe to RH front subframe crash can assembly

Note
2x bolts, 15mm, 53 Nm
Position the front stabar to front subframe and install the RH nuts securing it to subframe

Note
2x nyloc nuts, 15mm, 35 Nm, Recommend assistance, Install new nyloc nuts, Mark with paint pen
Install the LH nuts securing the front stabar to the front subframe

Note
2x nyloc nuts, 15mm, 35 Nm, Install new nyloc nuts, Mark with paint pen
Install the RH front axle shaft into the FDU

Note
1x axle
Install the LH front axle shaft into the FDU

Note
1x axle
Position the steering gear assembly to front subframe for installation
Loosely install inner bolts securing the steering gear assembly to front subframe

Note
2x bolts, 18mm, 75 Nm
Install outer bolts securing the steering gear assembly to front subframe

Note
2x bolts, 15mm, 27 Nm
Torque inner bolts securing the steering gear assembly to front subframe

Note
1x bolt, 18mm, 75 Nm
Position lifting tool and subframe under vehicle for installation
Connect air supply to subframe lifting tool
Install bolt securing the RH motor mount to the RH motor mount bracket

Note
1x bolt, E18, 105 Nm, May need adjust subframe jig to align mount with bolt hole
Install bolt securing the LH motor mount to the LH motor mount bracket

Note
1x bolt, E18, 105 Nm, May need adjust subframe jig to align mount with bolt hole
Raise support tool until the front subframe and body meet

Note
Recommend assistance, Guide the motor mount bushings into the motor mount isolators as the lift is being raised into position, Make sure to line up the rear locating pins on the subframe
Loosely install the RH larger bolt securing rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm, Install new bolt
Loosely install the LH larger bolt securing rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm, Install new bolt
Loosely install the RH smaller bolt securing rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install the LH smaller bolt securing rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install RH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm, Install new bolt, Adjust subframe lifting tool if necessary
Loosely install LH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm, Install new bolt, Adjust subframe lifting tool if necessary
Loosely install bolt securing the RH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install bolt securing the LH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install the bolts securing front end carrier to RH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Loosely install the bolts securing front end carrier to LH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Torque the RH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm
Torque the LH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm
Torque the RH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm
Torque the LH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm
Torque the RH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm
Torque the LH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm
Torque the bolt securing the RH mid mount to body

Note
1x bolt, 15mm, 50 Nm
Torque the bolt securing the LH mid mount to body

Note
1x bolt, 15mm, 50 Nm
Torque the bolts securing front subframe to RH front subframe crash can assembly

Note
2x bolts, 15mm, 53 Nm
Torque the bolts securing LH front subframe crash can assembly to front subframe

Note
2x bolts, 15mm, 53 Nm
Torque the bolts securing front end carrier to RH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Torque the bolts securing front end carrier to LH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Lower the subframe lifting tool from the vehicle

Note
Unlatch the subframe lifting tool from front subframe
Disconnect air supply from subframe lifting tool
Remove the subframe lifting tool from vehicle
Apply Molykote M-77 to outboard side of RH front halfshaft assembly

Note
Clean if necessary, Apply no more than 1 gram to axle only
Loosely install RH front halfshaft into RH front hub assembly

Note
1x nut, Install new nut and washer, Torqued at later step
Apply Molykote M-77 to outboard side of LH front halfshaft assembly

Note
Clean if necessary, Apply no more than 1 gram to halfshaft only
Loosely install LH front halfshaft into the LH front hub assembly

Note
1x nut, Install new nut and washer, Torqued at later step
Install the RH front lower lateral link and loosely install bolt and nut securing RH strut to lower control arm

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Loosely install bolts securing RH front lower lateral link to front subframe

Note
2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
Install the RH front lower comp link to front subframe
Install bolt and nut securing RH front lower comp link to front subframe

Note
1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
Torque bolts securing RH front lower lateral link to front subframe

Note
2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
Install LH front lower lateral link and loosely install bolt and nut securing LH strut to lower lateral link

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Loosely install bolts securing LH front lower lateral link to front subframe

Note
2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
Install LH front lower comp link to front subframe
Install bolt and nut securing LH front lower comp link to front subframe

Note
1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
Torque bolts securing LH front lower lateral link to front subframe

Note
2x bolts, 21mm, 115 Nm
Place FDU ground strap to original position and install bolt to HV battery

Note
1x bolt, 10mm, 10 Nm
Install FDU ground strap harness clip to FDU

Note
1x clip, Make sure to properly route the ground strap
Install bolt securing FDU ground strap to FDU

Note
1x bolt, 10mm, 6 Nm
Install FDU HV harness connector to FDU

Note
1x connector, Install HV connector lever lock to FDU HV cable connector, Align connector to FDU 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
Connect the FDU HV harness connector and lock the release lever

Note
1x clip, Apply slight pressure to the connector as the lever is rotated into position, Move the lever to the closed position slowly and ensure the lever teeth and manifold teeth are properly meshed, There should be a very small gap between the manifold and the connector when fully seated
Install bolt securing FDU HV harness to FDU

Note
1x bolt, 10mm, 10 Nm
Connect harness located at LH front rail bracket

Note
1x connector, Red locking tab, Connect from front of bracket and lock from opposite side of bracket, Image zoomed in for clarity
Install upper harness clip onto lower harness clip

Note
1x clip
Install lower harness clip into subframe

Note
1x clip
Connect the logic connectors below steering gear

Note
2x connectors, Engage locking tabs
Connect connectors to horn assembly

Note
2x connectors
Position coolant drain container below LH side of radiator
Remove plugs and connect coolant inlet hose to LH side of radiator

Note
1x spring clip
Position coolant drain container under RH side of FDU
Remove plugs and connect coolant hose from coolant bottle to oil cooler

Note
1x spring clip
Position coolant drain container underneath RH front of HV battery
Remove plugs and connect FDU coolant inlet hose at the RH side of vehicle

Note
1x spring clip
Remove coolant drain container from underneath vehicle
Position the RH front stabar link assembly to front stabar

Note
May be necessary to pull down on the sway bar to allow the end link to engage
Install nut securing front stabar to RH front stabar link assembly

Note
1x nyloc nut, 18mm, 98 Nm, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
Position LH front stabar link assembly to front stabar

Note
May be necessary to pull down on the sway bar to allow the end link to engage
Install nut securing front stabar link to LH front stabar

Note
1x nyloc nut, 18mm, 98 Nm, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
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
Position RH front tie rod end to RH front knuckle
Install nut securing RH front tie rod end to RH front knuckle

Note
1x nyloc nut, 22mm, 180 Nm, Install new nyloc nut
Position LH tie rod end to LH front knuckle
Install nut securing LH front tie rod end to LH front knuckle

Note
1x nyloc nut, 22mm, 180 Nm, Install new nyloc nut
Install front fascia onto vehicle and secure front clips and both front corners

Note
8x clips, Recommend assistance, Use caution not to damage headlamp or fender during installation
Connect 12V harness for front fascia

Note
1x locking connector, Engage locking tab
Connect pedestrian warning harness

Note
1x connector, 1x clip, Engage locking tab
Install bolt securing RH side of fascia to fender

Note
1x bolt, 10mm, 4 Nm
Install RH front wheel liner to vehicle

Note
14x clips
Install clips securing RH front wheel liner to vehicle

Note
14x clips
Install RH front fender garnish

Note
11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
Install RH front wheel

Note
5x nuts, 21mm, 175 Nm, Torque at later step
Install bolt securing LH side of fascia to fender

Note
1x bolt, 10mm, 4 Nm
Install LH front wheel liner to vehicle
Install LH front wheel liner clips securing LH front wheel liner to vehicle

Note
14x clips
Install LH front fender garnish

Note
11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
Install LH front wheel

Note
5x nuts, 21mm, 175 Nm, Torque at later step
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 front wheel liner to HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Install RH front wheel liner to HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Position the front aero shield to vehicle and install nuts

Note
2x nuts, 15mm, 5 Nm
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note
7x bolts, 10mm, 5 Nm
Lower vehicle until tires are just above the ground

Note
The front wheels should still move freely for aligning the intermediate shaft, Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Install fasteners holding upper portion of front fascia to vehicle

Note
5x bolts, 10mm, 4 Nm
Connect the steering gear assembly connectors

Note
2x locking connectors, Engage locking tab
Slide the intermediate shaft assembly downward to install it to the steering gear assembly

Note
Ensure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
Install bolt securing the intermediate shaft assembly to the steering gear assembly

Note
1x bolt, 13mm, 18 Nm
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 RH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque LH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque LH front halfshaft nut

Note
1x nut, 32mm, 245 Nm
Torque RH front halfshaft nut

Note
1x nut, 32mm, 245 Nm
Install RH front wheel cap

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

Note
1x cap, Align valve stem with wheel cap cavity
Remove coolant bottle cap
Place empty coolant container into front storage area
Fill container with at least 15L of coolant
Place filled coolant container into front storage area
Place coolant refill hose inside filled coolant container and make sure end is fully submerged
Install vacuum refill cap onto coolant bottle assembly
Close air inlet and coolant refill valves
Install vacuum refill hose into refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully installed
Place end of overflow hose into empty container
Place coolant refill hose inside filled coolant container and make sure end is fully submerged
Connect shop air supply to vacuum tool

Note
Minimum pressure 5.5 bar (80 psi)
Open air inlet valve for 10 seconds to create a vacuum, then fully close valve

Note
Gauge stabilizes roughly (24-27Hg)
Slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose, Close the valve when the hose is full of coolant

Note
This purges trapped air from the hose
Monitor gauge for 30 seconds to verify a vacuum is maintained in the cooling system
Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
Slowly open the coolant refill valve to allow coolant to be drawn into the system

Note
Make sure end of coolant refill hose is fully submerged during entire process
Once the gauge reads zero, close the coolant refill valve
Disconnect shop air supply from coolant refill tool
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle

Note
Push down on black ring to release hose and pull hose up to remove
Lift the coolant refill tool above coolant container to allow excess coolant to drain from hoses

Note
May need to reopen valves to remove all coolant
Remove both coolant containers from inside underhood area
Connect first responder loop and 12V negative terminal

Note
1x nut, 10mm, 6 Nm, 1x connector, Connect FRL first before connecting 12V to avoid damage to car computer
Remove the steering wheel holder
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
Thermal ➜ Coolant System ➜ Coolant Purge Start
via Service Mode Plus:
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
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. Coolant pump speeds can be monitored in Service Mode + (see Service Mode Plus), in the CAN Viewer submenu. 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
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE
via 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
Note
Select "X" at top right of window to close once complete.
Install frunk assembly into vehicle

Note
4x clips, Replace any clips if broken or missing
Install fasteners securing the frunk assembly

Note
5x bolts, 10mm, 5 Nm
Install access panel

Note
3x clips, 1x connector
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Move RH front seat to original position
Reposition 2nd row seat cushion

Note
Slide cushion rearward then align with buckles and foam with seat rail, Make sure cushion is fully seated with push & pull test
Move LH front seat to original position
Raise all windows
Close all four doors

Note
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
Torque bolt and nut securing LH strut to lower control arm

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Torque bolt and nut securing RH strut to lower control arm

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
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.

Model Y Service Manual

Subframe Assembly - Front (Dual Motor) (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3