30/09/2024 17:24:10

Fluid Coupling (Straight) - Rear Drive Unit (Remove and Replace)

Correction code 40014202 0.72 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.

  • 2023-06-14: Added shear plate small bolts torque figure for Structural Pack vehicles.
  • 2023-10-12: Re-structured the procedure.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
Table 1. Torque Specifications: Fluid Coupling (Straight) - Rear Drive Unit (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the rear drive unit ground strap to the body
10 Nm (7.4 lbs-ft)
  • Ratchet/torque wrench
  • 10 mm 12-point deep socket
Reuse
Bolt that secures the rear drive unit HV cable bracket to the drive unit
6 Nm (4.4 lbs-ft)
  • Ratchet/torque wrench
  • 10 mm socket
Reuse
Nut that secures the rear drive unit HV cable bracket to the HV battery
10 Nm (7.4 lbs-ft)
  • Ratchet/torque wrench
  • 10 mm socket
  • 6 in extension
  • Cordless Ratchet/Impact Driver
  • ¼ in hex to ¼ in square 6 in adapter
Reuse
Bolts that attach the rear subframe to the body
165 Nm (121.7 lbs-ft)
  • Ratchet/torque wrench
  • 6 in extension
  • 21 mm socket
  • Subframe Fixture - 1099645-00-C
  • Powertrain Table - 1066521-00-A
Reuse
LH mount bolt that secures the drive unit to subframe
80 Nm (59.0 lbs-ft)
  • Ratchet/torque wrench
  • 18 mm socket
  • Prybar Med
  • 18 mm deep socket
  • Cordless Ratchet/Impact Driver
  • Flex head ratchet/flex head torque wrench
Reuse
Bolts on the rear drive unit LH mount assembly
35 Nm (25.8 lbs-ft) and 55 degrees
  • Ratchet/torque wrench
  • 3 in extension
  • External Torx E14
  • Cordless Ratchet/Impact Driver
  • Torque wrench with angle measurement
Reuse
Bolt that secures the outlet fitting to manifold
6 Nm (4.4 lbs-ft)
  • Ratchet/torque wrench
  • 4 in extension
  • Torx T25 socket
Replace

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Open all doors and lower the windows.
  3. Connect a laptop with Toolbox 3.0 to the vehicle.
  4. Select the Actions/Autodiag tab and search for ‘Fill Drain’.
  5. Select PROC_VCFRONT_X_THERMAL-FILL-DRAINSearch for routine in Toolbox, click Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    This will ensure the octovalve is in the Series position. Coolant pumps will also be disabled. Once "Run" is selected, the routine is in progress despite the prompt with loading circle. Routine will time out after several hours and return valves to parallel position if unattended. Close the routine once it is complete.
  6. Remove the laptop from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not close Toolbox 3.0, its use is resumed later.
  7. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
  8. Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  9. Remove the LH and RH suspension cover. See Cover - Rear Suspension - LH (Remove and Replace).
  10. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  11. Remove the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  12. Release the locking tab to disconnect the RH side 12V subframe harness connector.
  13. Remove the RH side 12V subframe harness clip from body.
  14. Disconnect the electrical harness from the LH 12V subframe connector.
  15. Release the clip that attaches the LH subframe electrical harness to the body.
  16. Remove the nut that attaches the rear drive unit ground strap to the body.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm 12-point deep socket
  17. Remove the rear stabilizer bar. See Stabilizer Bar - Rear (Remove and Replace).
  18. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  19. Position a coolant drain container under the LH rear of the HV battery.
  20. Disconnect the rear drive unit inverter inlet hose from the LH rear side of the HV battery, and then plug the male and female fittings.
  21. Disconnect the rear drive unit inverter inlet tube from the fluid coupling.
  22. Release the fir free clip that attaches the rear drive unit inverter inlet tube to the rear drive unit HV cable harness.
  23. Remove the rear drive unit inverter inlet hose from between subframe and drive unit.
  24. Remove the coolant drain container from underneath the vehicle.
  25. Release the rear drive unit logic connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not get coolant ingress into this connector. Move aside as needed.
  26. Release the rear drive unit logic connection clip.
  27. Remove the bolt that secures the rear drive unit HV cable bracket to the drive unit.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm socket
  28. Release the red locking tab, and then disconnect the connector that attaches the rear drive unit HV cable to the drive unit.
  29. Remove the nut that attaches the HV cable bracket to the HV battery.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm socket
    • 6 in extension
    • Cordless Ratchet/Impact Driver
    • ¼ in hex to ¼ in square 6 in adapter
  30. Slide the release to unlock the HV battery rear drive unit connector handle of the rear drive unit to HV battery harness from the secured position.
  31. Fully raise the handle on the HV battery rear drive unit connector, and then remove the HV battery rear drive unit connector from the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the release lever up. Ensure the alignment tabs on the rear drive unit header are not damaged.
  32. Remove the rear drive unit HV harness from between subframe and drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the HV harness between subframe and battery pack. Rotate as needed for clearance.
  33. Place the subframe lifting tool into position underneath the rear subframe, and connect air supply to the tool.
  34. With assistance, raise the subframe lifting tool to support the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure. Lower the vehicle if necessary.
  35. Mark the LH rear and RH rear subframe bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Re-align during install. Also mark subframe casting and subframe bushing to body if needed.
  36. Remove the LH and RH shear plates. See Shear Plate - Rear Subframe - Front - LH (Remove and Replace).
  37. Remove the bolts (x2) that attach the rear subframe to the body.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 6 in extension
    • 21 mm socket
    • Subframe Fixture - 1099645-00-C
    • Powertrain Table - 1066521-00-A
  38. Partially lower the rear subframe and drive unit assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful while lowering the subframe as multiple components are still attached. Do not overstrain these components. The dampers and brake calipers are still connected. Recommend lowering about 3.25in or 8.25cm.
  39. Tilt the subframe fixture forward.
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the powertrain lift and tilt it forward in order to access motor mount fasteners.
  40. Support the center of the rear drive unit with protective.
    Informational PurposesAn informational icon, calling your attention
    Note
    Using a rubber or wood block. Do not damage the drive unit.
  41. Remove the LH mount bolt that secures the drive unit to subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the fastener and use a pry to aid as needed. Do not damage the drive unit casting.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 18 mm socket
    • Prybar Med
    • 18 mm deep socket
    • Cordless Ratchet/Impact Driver
    • Flex head ratchet/flex head torque wrench
  42. Release the rear drive unit ground strap clip from the subframe.
  43. Release the inverter to cooler hose clip and plug the ends of fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a flex head ratchet/flex head torque wrench to release the clip on the hose, and then release the hose.
  44. Remove the bolts (x3) on the rear drive unit LH mount assembly.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 3 in extension
    • External Torx E14
    • Cordless Ratchet/Impact Driver
    • Torque wrench with angle measurement
  45. Maneuver upwards and remove the LH mount assembly from between the rear drive unit and subframe.
  46. Remove and discard the bolt that secures the outlet fitting to manifold.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 4 in extension
    • Torx T25 socket
  47. Remove the straight fluid coupling from the drive inverter assembly.

Install

  1. Lubricate the straight fluid coupling O-ring with coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not install the fluid coupling with the O-ring dry.
  2. Install the straight fluid coupling into the drive inverter assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take care not to damage the sealing ring. Use a fluid coupling cap to assist with installation. Ensure the straight fluid coupling is seated properly into the drive inverter assembly.
  3. Install the bolt that secures the outlet fitting to manifold.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 4 in extension
    • Torx T25 socket
  4. Install coolant pressure test plug adapter to the straight fluid coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking clip is fully seated.
  5. Install the coolant pressure adapter to the 55 degrees fluid coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking clip is fully seated.
  6. Attach the coolant pressure tester to the pressure fitting adapter.
  7. Attach the coolant pressure tester to the compressed air line.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the valves are closed on the pressure regulator.
  8. Set the pressure regulator to 50 psi.
  9. Slowly open the valve on pressure regulator and allow the pressure to reach specification.
  10. Close the valve and wait for 16 seconds to let the pressure test settle, and then record the reading.
  11. Wait for another 12 seconds and record the reading.
    Informational PurposesAn informational icon, calling your attention
    Note
    The delta should not be greater than 0.10 psi. Check the coolant hose to see if it is fully seated or not if the pressure test fails.
  12. Disconnect the compressed air from coolant pressure tester.
  13. Remove the pressure fitting adapter from the coolant pressure tester.
  14. Remove the coolant pressure tester from the 55 degrees fluid coupling.
  15. Remove the coolant pressure test plug adapter from the straight fluid coupling.
  16. Position the LH mount assembly in between the rear drive unit and the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver between the drive unit and subframe.
  17. Install and torque the bolts to secure the LH mount assembly.
    35 Nm (25.8 lbs-ft) and 55 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Follow the torque sequence per image.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 3 in extension
    • External Torx E14
    • Cordless Ratchet/Impact Driver
    • Torque wrench with angle measurement
  18. Install the LH mount bolt that secures the drive unit to subframe.
    80 Nm (59.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 18 mm socket
    • Prybar Med
    • 18 mm deep socket
    • Cordless Ratchet/Impact Driver
    • Flex head ratchet/flex head torque wrench
  19. Remove the center support from the rear drive unit.
  20. Secure the spring clip, plugs (x2) and the clip that attach the inverter to cooler hose to the inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure hose is fully engaged
  21. Secure the rear drive unit ground strap clip onto subframe.
  22. Tilt the subframe fixture backwards to original position.
  23. Raise the partially lowered subframe.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use caution to not damage components while raising subframe.
  24. Hand-tighten the new bolts (x2) that attach the rear subframe to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    The tightening of the bolts will be performed later in this procedure.
  25. Install the LH and RH shear plates. See Shear Plate - Rear Subframe - Front - LH (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Terminate before installing the mid aero shield panel.
  26. Position the subframe to the marked location.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use previous markings to align the subframe to body. Return to original position as close as possible.
  27. Torque the bolts that attach the LH and RH rear subframe to the body, and then mark them with a paint pen after torquing.
    165 Nm (121.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 6 in extension
    • 21 mm socket
    • Subframe Fixture - 1099645-00-C
    • Powertrain Table - 1066521-00-A
  28. Lower the rear subframe lifting tool from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the yellow safety straps are removed from the subframe.
  29. Disconnect air supply from the subframe lifting tool.
  30. Remove the subframe lifting tool from underneath the vehicle.
  31. Position the rear drive unit HV harness for install between subframe and drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the HV harness into position and rotate as needed.
  32. Connect the rear drive unit HV cable to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    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 the other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position.
  33. Install the nut that secures the rear drive unit HV cable bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm socket
    • 6 in extension
    • Cordless Ratchet/Impact Driver
    • ¼ in hex to ¼ in square 6 in adapter
  34. Connect the rear drive unit HV cable to the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the HV connector lever lock to the rear drive unit HV cable connector. Align the connector to drive unit, and then remove the HV connector lever lock before fully latching the connector. Use one hand to support the connector while the other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position.
  35. Install the bolt that secures the rear drive unit HV cable bracket to the drive unit.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm socket
  36. Secure the rear drive unit logic connection clip.
  37. Secure the rear drive unit logic connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify there is no coolant ingress in the connector.
  38. Position a coolant drain container underneath the LH rear of HV battery.
  39. Position the rear drive unit inverter inlet hose for installation between subframe and drive unit.
  40. Secure the rear drive unit inverter inlet hose clip onto the HV cable.
  41. Remove the plugs and connect the rear drive unit inverter inlet hose to the rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure the hose is fully seated.
  42. Remove the hose plugs and connect the coolant inlet hose to rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Let the coolant drain from hose before install. Perform a push-pull-push test to make sure hose is fully seated.
  43. Remove the coolant drain container from underneath the vehicle.
  44. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  45. Install the rear stabilizer bar. See Stabilizer Bar - Rear (Remove and Replace).
  46. Install the nut that attaches the rear drive unit ground strap to the body.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm 12-point deep socket
  47. Install the LH and RH side 12V subframe harness clips to body.
  48. Engage the locking tabs to connect the LH and RH side 12V subframe harness connectors.
  49. Install the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  50. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  51. Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  52. Lower the vehicle to a comfortable working height and set the lift onto locks.
  53. Perform a vacuum refill. See Cooling System (Vacuum Refill).
  54. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  55. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  56. Move LH and RH front seats to original position.
  57. Connect a laptop with Toolbox 3. See Toolbox 3 (Connect and Disconnect).
  58. On the laptop, select the Actions/Autodiag tab and search for ‘Thermal’, select Search for routine in Toolbox, click Run, and allow the routine to complete.
  59. Search for "Purge", click TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start, and then click Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • The speed can be monitored in Garage under the PT Thermal tab. If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  60. Disconnect the laptop from the vehicle.
  61. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "MAX" line, and the coolant is filled using G-48 coolant.
  62. Install the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  63. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  64. Raise all windows and close all doors.
  65. Remove the vehicle from the lift.
  66. Review the wheel alignment requirements and add correction code as needed. See Alignment Requirement - Suspension.