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
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Raise and support vehicle
NoteEnsure 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
Note14x clips
-
Power off vehicle from center
display
NoteVia Controls > Safety & Security > Vehicle Power > Power Off
-
Disconnect 12V negative terminal and
first responders loop
Note1x 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
Note1x 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
Note5x nuts, 21mm, 175 Nm
- Close LH front door
-
Raise vehicle partially and lower lift
onto locks
NoteSet 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
Note5x nuts, 21mm, 175 Nm
-
Remove RH rear brake caliper from
knuckle and hang from body
Note2x bolts, E18, 83 Nm, Discard bolts after removal
-
Raise vehicle fully and lower lift
onto locks
NoteSet 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
Note11x bolts, 10mm, 5 Nm
-
Remove RH rear suspension cover
Note1x bolt, 10mm, 6 Nm, 2x tabs
-
Lower vehicle partially and set lift
onto locks
NoteRaise 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
Note2x bolts, 15mm, 41 Nm
-
Remove nut securing RH rear stabilizer
bar end link to stabilizer bar
Note1x 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
NoteMay 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
Note1x patch bolt, 10mm, 5 Nm, Discard after removal,1x grommet
-
Remove nut and bolt securing RH rear
upper aft link to RH rear knuckle
Note1x bolt, 1x nut, 21mm, 134 Nm
-
Remove nut and bolt securing RH rear
upper fore link to RH rear knuckle
Note1x bolt, 1x nut, 18mm, 76 Nm
-
Remove nut and bolt securing RH rear
toe link to RH rear knuckle
Note1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance
-
Remove nut and bolt securing RH rear
lower fore link to RH rear knuckle
Note1x bolt, 1x nut, 18mm, 76 Nm
-
Release RH halfshaft from drive
unit
Note1x 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
NoteRecommend assistance, Install axle seal plug
-
Install axle seal plug
-
Raise vehicle fully and lower lift
onto locks
NoteSet 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
Note1x fir tree clip
-
Disconnect lower coolant hose to
exchanger
Note1x 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
Note1x fir tree clip
-
Disconnect upper coolant hose to
exchanger
Note1x 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
Note2x 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
NoteDo 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
NoteLightly 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
Note1x spring clip, Perform push-pull-push test to make sure hose is fully seated
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Fasten fir tree clip for upper coolant hose
Note1x fir tree clip
-
Secure coolant outlet hose to drive unit cooler
Note1x spring clip, Perform push-pull-push test to make sure hose is fully seated
-
Fasten fir tree clip for lower hose
Note1x fir tree clip, Remove used shop towels
- Remove coolant drain container from underneath vehicle
-
Lower vehicle partially and set onto locks
NoteRaise 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
NoteRemove 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
NoteClean 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
Note1x 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
Note1x 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
Note1x 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
Note1x nut, 18mm, 76 Nm, Torque at later step
-
Install RH rear wheel speed sensor to knuckle
Note1x patch bolt, 10mm, 5 Nm, Install new patch bolt,1x grommet
-
Position RH rear end link into stabilizer bar
NoteAdjust 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
Note1x 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
Note2x bolts, 15mm, 41 Nm
-
Install RH rear brake caliper onto knuckle
Note2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
-
Remove bolt securing RH rotor to hub
Note1x bolt, 10mm, 5 Nm
-
Install hub jack adapter onto RH rear hub
Note5x lug nuts, 21mm, Hand tight
-
Position and raise support stand to simulate RH rear suspension at ride height
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Use rear ride height torque gauge to verify RH suspension is set to ride height specification
NoteMay 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
NoteDistance should be 427 mm
-
Torque bolt securing RH rear toe link to knuckle
Note1x bolt, 18mm, 76 Nm, Mark with paint pen
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Torque bolt securing RH rear upper fore link to knuckle
Note1x bolt, 18mm, 76 Nm, Mark with paint pen
-
Torque bolt securing RH rear lower fore link to knuckle
Note1x bolt, 18mm, 76 Nm, Mark with paint pen
-
Torque bolt securing RH rear upper aft link to knuckle
Note1x bolt, 21mm, 134 Nm, Mark with paint pen
-
Remove support stand from underneath RH suspension
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Remove hub jack adapter from RH rear hub
Note5x lug nuts, 21mm, Hand tight
-
Install bolt securing RH rotor to hub
Note1x bolt, 10mm, 5 Nm
-
Remove spring compressor from RH rear coil spring
-
Raise vehicle fully and lower lift onto locks
NoteSet 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
Note1x 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
Note1x connector
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Remove fill plug from RDU
Note1x 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
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Pull out dipstick to verify fluid is at correct level
NoteMake fluid level adjustment if necessary
-
Install fill plug into RDU
NoteInstall new fill plug O-ring, 1x plug, 8mm Allen, 15 Nm
-
Disconnect 12V power supply tool from oil pump
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Connect oil pump connector
Note1x connector, Engage locking tab
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Install RH rear suspension cover
Note1x bolt, 10mm, 6 Nm, 2x tabs
-
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
Note9x bolts, 10mm, 5 Nm
-
Lower vehicle partially and set onto locks
NoteRaise 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
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Lower vehicle until tires are touching the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Torque RH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Install RH rear wheel cap
Note1x cap, Align valve stem with wheel cap cavity
-
Remove coolant bottle cap
-
Inspect coolant level and top off as necessary
NoteEnsure that the fluid level is at the Max line
-
Connect first responder loop and 12V negative terminal
Note1x 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
NoteRemove wheel chocks if necessary
- Open LH front door
- Connect to vehicle using Toolbox 3.0
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Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
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Select
‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
- Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
- Thermal ➜ Coolant System ➜ Coolant Purge Start
- 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
NoteMake 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
NoteEnsure that the fluid level is at the Max line
-
Install coolant bottle cap
-
Install rear apron
Note14x 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
NoteLower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
-
Check tire pressures
Note4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar
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Verify the alignment slip/turn plates are locked
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Drive vehicle onto alignment rack
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Pull vehicle forward and stop ~ 0.5 ft before turn plates to allow for rolling compensation
NoteShift to park
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Shift to park
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Install wheel chocks
NotePlace chocks on both sides of the driver's side rear tire
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Latch the driver seat belt to buckle
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Latch LH front door and place vehicle into neutral
NoteCareful not to slam the door while latch is engaged
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Raise alignment rack partially and lower to lock position
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Install alignment heads onto wheels
Note4x alignment heads
- Enter vehicle information to alignment machine
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Perform rolling compensation
NoteRemove 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
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Verify chassis height measurement tool is calibrated
NoteAdjust if necessary, Measure height of tool and adjust reading to match
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Perform ride height measurement
NoteMeasure 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
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Perform caster sweep and install steering wheel holder and level tool
NoteIf camber and caster are out of specification, perform necessary camber and caster adjustment
-
Verify alignment reading is within specification and print vehicle summary
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Remove alignment heads from wheels
Note4x alignment heads
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Remove brake pedal depressor
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Lock alignment slip/turn plates
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Lower the alignment rack to ground
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Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
-
Unlatch LH front seat belt
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Remove wheel chocks
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Remove vehicle from alignment rack