08/12/2023 05:35:57

Brake Pedal (Structural Pack) (Remove and Replace)

Correction code 33251022 0.66 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.

2023-12-08: Removed brake stiffness routine.

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 the LH front door and lower the LH front window
Move LH front seat backward
Open hood
Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Remove bolt securing frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Release washer tank neck from washer tank and set aside

Note
1x O-ring, No need to remove hose from neck
Remove HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
Remove LH front floormat
Remove LH console side panel carpet

Note
11x clips, 2x guide pins, Use trim tool starting at top edge to release upper clips, then pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
Remove the driver knee airbag. See Airbag - Knee - Driver (Remove and Install)
Remove the LH footwell air duct
Disconnect brake switch

Note
1x connector
Remove brake switch from pedal assembly

Note
Twist counter clockwise 45 degrees to remove. Replace if damaged during removal
Remove cotter clip from clevis pin on brake pedal assembly

Note
1x clip
Remove clevis pin from brake pedal assembly

Note
1x pin
Disconnect accelerator pedal connector

Note
1x connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Remove clip securing pedal harness to pedal assembly

Note
1x clip
Remove inner nuts securing pedal assembly to superdash

Note
2x nuts, 13mm, 16.5 Nm, Discard nyloc nuts after removal
Remove outer nuts securing pedal assembly to superdash

Note
3x nuts, 13mm, 16.5 Nm, Located under cowl, Discard nyloc nuts after removal
Remove pedal assembly

Note
2x studs, Release from iBooster studs then negotiate around iBooster rod
Position pedal assembly

Note
2x studs, Negotiate around iBooster rod then secure onto iBooster studs
Install outer nuts securing pedal assembly to superdash

Note
3x nuts, 13mm, 16.5 Nm, Located under cowl, Install new nyloc nuts
Install inner nuts securing pedal assembly to superdash

Note
2x nuts, 13mm, 16.5 Nm, Install new nyloc nuts
Install clip securing pedal harness to pedal assembly

Note
1x clip
Connect accelerator pedal connector

Note
1x connector, Engage locking tab
Align brake pedal to iBooster rod and install clevis pin to brake pedal assembly

Note
1x pin
Install cotter pin into clevis pin clip on brake pedal assembly

Note
1x clip
Install new brake switch clip into the new pedal assembly

Note
1x clip
Install brake switch onto pedal assembly

Note
Confirm that the brake pedal is in the home position, iBooster and Brake Pedal must be assembled together for brake light switch to be installed, Push the brake switch into the clip until it stops (don't push so hard as to move the brake pedal), Twist clockwise 45 degrees to set the brake switch, Make sure brake switch connector facing RH side of vehicle with connector pins vertical
Connect brake switch connector

Note
1x connector
Install the LH footwell duct into HVAC module
Connect the driver knee air bag and install into vehicle

Note
1x connector, Use caution not to damage the connector/harness, Support the knee air bag while connecting the connector
Install fasteners securing driver knee air bag to vehicle

Note
4x patch bolts, E10, 8 Nm, Install new patch bolts, 2x screws, T20, 2 Nm, 2x push clips
Install connectors to LH footwell cover and position for installation

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector
Install screw and clips securing LH footwell cover

Note
1x screw, T20, 2.5 Nm, 2x push clips
Install LH console side panel carpet

Note
11x clips, 2x locating pins, Position side panel and align the front into front locator, then the rear locator, Push side panel towards console to install
Install LH front floormat
Connect first responder loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Install HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
Install washer tank neck to washer tank

Note
1x O-ring, Ensure washer hose is properly routed after installation
Secure frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Close hood
Move LH front seat to original position
Raise LH front window
Close LH front door