01/04/2024 13:58:45

Heat Exchanger - Rear Drive Unit (3DU) (Remove and Replace)

Correction code 40305202 1.74 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.

2024-02-27: Updated gearbox fluid to KAF 1.
2023-08-16: Updated EPB Service Mode reference.

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 the LH front door and lower the LH front window.
Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
Open hood
Remove rear apron

Note
14x clips
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
Remove RH rear 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 rear wheel

Note
5x nuts, 21mm, 175 Nm
Close LH front door
Raise vehicle partially and lower lift onto locks

Note
Set vehicle to a 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 RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH rear brake caliper from knuckle and hang from body

Note
2x bolts, E18, 83 Nm, Discard bolts after removal
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 mid aero shield

Note
11x bolts, 10mm, 5 Nm
Remove RH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
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 spring compressor onto RH rear coil spring
Unbolt RH strut from body at top mount

Note
2x bolts, 15mm, 41 Nm
Remove nut securing RH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from RH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
Remove RH rear wheel speed sensor from RH rear knuckle

Note
1x patch bolt, 10mm, 5 Nm, Discard after removal，1x grommet
Remove nut and bolt securing RH rear upper aft link to RH rear knuckle

Note
1x bolt, 1x nut, 21mm, 134 Nm
Remove nut and bolt securing RH rear upper fore link to RH rear knuckle

Note
1x bolt, 1x nut, 18mm, 76 Nm
Remove nut and bolt securing RH rear toe link to RH rear knuckle

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance
Remove nut and bolt securing RH rear lower fore link to RH rear knuckle

Note
1x bolt, 1x nut, 18mm, 76 Nm
Release RH halfshaft from drive unit

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
Remove RH halfshaft from rear drive unit

Note
Recommend assistance, Install axle seal plug
Install axle seal plug
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
Place coolant drain container underneath vehicle
Release fir tree clip for lower coolant hose

Note
1x fir tree clip
Disconnect lower coolant hose to exchanger

Note
1x spring clip, Place a shop towel under the exchanger, Allow heat exchanger to drain, Allow hose to drain, Plug hose afterwards
Release fir tree clip for upper coolant hose

Note
1x fir tree clip
Disconnect upper coolant hose to exchanger

Note
1x spring clip, Allow heat exchanger to drain, Allow hose to drain, Plug hose afterwards
Remove the fasteners securing the heat exchanger to the drive unit

Note
2x bolts, EP10, 5 Nm + 30 degrees, The number of fasteners may vary due to production changes
Remove the heat exchanger from the drive unit assembly

Note
Do not pry against the RDU or the heat exchanger, Damage may occur, It may be necessary to gently work the heat exchanger up and down to free it from the RDU, Do not allow coolant to enter oil passages of drive unit, Prevent cross-contamination

Install

Install the heat exchanger onto the rear drive unit

Note
Lightly coat o-rings with clean KAF 1 gearbox fluid. Do not pinch or deform o-ring during install, Ensure the heat exchanger is fully seated, Do not allow coolant to enter oil passages of drive unit, Prevent cross-contamination
Secure inverter to cooler hose to cooler

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Fasten fir tree clip for upper coolant hose

Note
1x fir tree clip
Secure coolant outlet hose to drive unit cooler

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Fasten fir tree clip for lower hose

Note
1x fir tree clip, Remove used shop towels
Remove coolant drain container from underneath vehicle
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
Install RH halfshaft to drive unit

Note
Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
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
Install RH rear toe link to knuckle and install nut and bolt hand tight

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
Install RH rear upper fore link to knuckle and install nut and bolt hand tight

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
Install RH upper aft link to knuckle and install nut and bolt hand tight

Note
1x bolt, 1x nut, 21mm, 134 Nm, Recommend assistance, Torque at later step
Install RH rear lower fore link to knuckle and install nut and bolt hand tight

Note
1x nut, 18mm, 76 Nm, Torque at later step
Install RH rear wheel speed sensor to knuckle

Note
1x patch bolt, 10mm, 5 Nm, Install new patch bolt，1x grommet
Position RH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing RH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
Install bolts securing RH damper to body at top mount

Note
2x bolts, 15mm, 41 Nm
Install RH rear brake caliper onto knuckle

Note
2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
Remove bolt securing RH rotor to hub

Note
1x bolt, 10mm, 5 Nm
Install hub jack adapter onto RH rear hub

Note
5x lug nuts, 21mm, Hand tight
Position and raise support stand to simulate RH rear suspension at ride height
Use rear ride height torque gauge to verify RH suspension is set to ride height specification

Note
May need to slightly adjust stand or compression tool
Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height

Note
Distance should be 427 mm
Torque bolt securing RH rear toe link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing RH rear upper fore link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing RH rear lower fore link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing RH rear upper aft link to knuckle

Note
1x bolt, 21mm, 134 Nm, Mark with paint pen
Remove support stand from underneath RH suspension
Remove hub jack adapter from RH rear hub

Note
5x lug nuts, 21mm, Hand tight
Install bolt securing RH rotor to hub

Note
1x bolt, 10mm, 5 Nm
Remove spring compressor from RH rear coil spring
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
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
Connect the 12V power supply to oil pump

Note
1x connector
Remove fill plug from RDU

Note
1x plug, 8mm Allen, 15 Nm
Install dipstick into fill port
Run the oil pump power supply for 1 minute
Wait 1 minute for fluid to settle
Pull out dipstick to verify fluid is at correct level

Note
Make fluid level adjustment if necessary
Install fill plug into RDU

Note
Install new fill plug O-ring, 1x plug, 8mm Allen, 15 Nm
Disconnect 12V power supply tool from oil pump
Connect oil pump connector

Note
1x connector, Engage locking tab
Install RH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note
9x bolts, 10mm, 5 Nm
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
Install RH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
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 rear wheel

Note
5x nuts, 21mm, 175 Nm
Install RH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Remove coolant bottle cap
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Connect first responder loop and 12V negative terminal

Note
1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
Press and hold park button to release EPB service mode

Note
Remove wheel chocks if necessary
Open LH front door
Connect to vehicle using Toolbox 3.0
Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
Select ‘Coolant Air PurgeTEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEGen3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE Model3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGELow Voltage Controllers Low Voltage ControllersThermal / Actions - Coolant Air PurgeService Mode Service Plus Factory Mode Developer Thermal / Coolant System - Coolant Air PurgeService Mode Service Plus Factory Mode Developer hv / Procedures - Transport Service Plus Developer ’, click ‘Run’, and allow routine to complete

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, 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
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Raise LH front window
Close LH front door
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
Pull vehicle forward and stop ~ 0.5 ft before turn plates to allow for rolling compensation

Note
Shift to park
Shift to park
Install wheel chocks

Note
Place chocks on both sides of the driver's side rear tire
Latch the driver seat belt to buckle
Latch LH front door and place vehicle into neutral

Note
Careful not to slam the door while latch is engaged
Raise alignment rack partially and lower to lock position
Install alignment heads onto wheels

Note
4x alignment heads
Enter vehicle information to alignment machine
Perform rolling compensation

Note
Remove the wheel chocks from the LH rear tire and push the back of the tire to roll vehicle forward. Reinstall wheel chocks once vehicle is in position
Unlock alignment slip/turn plates
Verify chassis height measurement tool is calibrated

Note
Adjust if necessary, Measure height of tool and adjust reading to match
Perform ride height measurement

Note
Measure the ride height 75mm inward of the HV battery ski hole at each corner, If using ballast bags, move the front seats as necessary to achieve ride height spec, See Service Manual for ride height specifications
Apply brake pedal depressor
Perform caster sweep and install steering wheel holder and level tool

Note
If camber and caster are out of specification, perform necessary camber and caster adjustment
Verify alignment reading is within specification and print vehicle summary
Remove alignment heads from wheels

Note
4x alignment heads
Remove brake pedal depressor
Lock alignment slip/turn plates
Lower the alignment rack to ground
Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
Unlatch LH front seat belt
Remove wheel chocks
Remove vehicle from alignment rack