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.
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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

  1. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
  2. Open the LH front door and lower the LH front window.
  3. Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
  4. Open hood
  5. Remove rear apron
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    Note
    14x clips
  6. Power off vehicle from center display
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    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off
  7. Disconnect 12V negative terminal and first responders loop
    Informational PurposesAn informational icon, calling your attention
    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
  8. Remove RH rear wheel cap
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    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  9. Loosen RH rear wheel
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    Note
    5x nuts, 21mm, 175 Nm
  10. Close LH front door
  11. Raise vehicle partially and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  12. Remove RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  13. Remove RH rear brake caliper from knuckle and hang from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E18, 83 Nm, Discard bolts after removal
  14. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  15. Remove mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm
  16. Remove RH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  17. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  18. Install spring compressor onto RH rear coil spring
  19. Unbolt RH strut from body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm
  20. Remove nut securing RH rear stabilizer bar end link to stabilizer bar
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    Note
    1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
  21. Remove stabilizer bar from RH rear end link
    Informational PurposesAn informational icon, calling your attention
    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
  22. Remove RH rear wheel speed sensor from RH rear knuckle
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    Note
    1x patch bolt, 10mm, 5 Nm, Discard after removal,1x grommet
  23. Remove nut and bolt securing RH rear upper aft link to RH rear knuckle
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    Note
    1x bolt, 1x nut, 21mm, 134 Nm
  24. Remove nut and bolt securing RH rear upper fore link to RH rear knuckle
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    Note
    1x bolt, 1x nut, 18mm, 76 Nm
  25. Remove nut and bolt securing RH rear toe link to RH rear knuckle
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    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance
  26. Remove nut and bolt securing RH rear lower fore link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm
  27. Release RH halfshaft from drive unit
    Informational PurposesAn informational icon, calling your attention
    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
  28. Remove RH halfshaft from rear drive unit
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    Note
    Recommend assistance, Install axle seal plug
  29. Install axle seal plug
  30. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  31. Place coolant drain container underneath vehicle
  32. Release fir tree clip for lower coolant hose
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    Note
    1x fir tree clip
  33. Disconnect lower coolant hose to exchanger
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    Note
    1x spring clip, Place a shop towel under the exchanger, Allow heat exchanger to drain, Allow hose to drain, Plug hose afterwards
  34. Release fir tree clip for upper coolant hose
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    Note
    1x fir tree clip
  35. Disconnect upper coolant hose to exchanger
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    Note
    1x spring clip, Allow heat exchanger to drain, Allow hose to drain, Plug hose afterwards
  36. Remove the fasteners securing the heat exchanger to the drive unit
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    Note
    2x bolts, EP10, 5 Nm + 30 degrees, The number of fasteners may vary due to production changes
  37. Remove the heat exchanger from the drive unit assembly
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    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

  1. Install the heat exchanger onto the rear drive unit
    Informational PurposesAn informational icon, calling your attention
    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
  2. Secure inverter to cooler hose to cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  3. Fasten fir tree clip for upper coolant hose
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    Note
    1x fir tree clip
  4. Secure coolant outlet hose to drive unit cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  5. Fasten fir tree clip for lower hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip, Remove used shop towels
  6. Remove coolant drain container from underneath vehicle
  7. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  8. Install RH halfshaft to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
  9. Apply Molykote M-77 to outboard side of RH front halfshaft assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean if necessary, Apply no more than 1 gram to axle only
  10. Install RH rear toe link to knuckle and install nut and bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
  11. Install RH rear upper fore link to knuckle and install nut and bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
  12. Install RH upper aft link to knuckle and install nut and bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm, Recommend assistance, Torque at later step
  13. Install RH rear lower fore link to knuckle and install nut and bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 18mm, 76 Nm, Torque at later step
  14. Install RH rear wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm, Install new patch bolt,1x grommet
  15. Position RH rear end link into stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    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
  16. Install nut securing RH rear end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
  17. Install bolts securing RH damper to body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm
  18. Install RH rear brake caliper onto knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
  19. Remove bolt securing RH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  20. Install hub jack adapter onto RH rear hub
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    Note
    5x lug nuts, 21mm, Hand tight
  21. Position and raise support stand to simulate RH rear suspension at ride height
  22. Use rear ride height torque gauge to verify RH suspension is set to ride height specification
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to slightly adjust stand or compression tool
  23. Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height
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    Note
    Distance should be 427 mm
  24. Torque bolt securing RH rear toe link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  25. Torque bolt securing RH rear upper fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  26. Torque bolt securing RH rear lower fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  27. Torque bolt securing RH rear upper aft link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 134 Nm, Mark with paint pen
  28. Remove support stand from underneath RH suspension
  29. Remove hub jack adapter from RH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  30. Install bolt securing RH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  31. Remove spring compressor from RH rear coil spring
  32. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  33. Disconnect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
  34. Connect the 12V power supply to oil pump
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    Note
    1x connector
  35. Remove fill plug from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x plug, 8mm Allen, 15 Nm
  36. Install dipstick into fill port
  37. Run the oil pump power supply for 1 minute
  38. Wait 1 minute for fluid to settle
  39. Pull out dipstick to verify fluid is at correct level
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    Note
    Make fluid level adjustment if necessary
  40. Install fill plug into RDU
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    Note
    Install new fill plug O-ring, 1x plug, 8mm Allen, 15 Nm
  41. Disconnect 12V power supply tool from oil pump
  42. Connect oil pump connector
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    Note
    1x connector, Engage locking tab
  43. Install RH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  44. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
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    Note
    9x bolts, 10mm, 5 Nm
  45. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  46. Install RH rear wheel
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    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  47. Lower vehicle until tires are touching the ground
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  48. Torque RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  49. Install RH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  50. Remove coolant bottle cap
  51. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  52. Connect first responder loop and 12V negative terminal
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    Note
    1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
  53. Press and hold park button to release EPB service mode
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    Note
    Remove wheel chocks if necessary
  54. Open LH front door
  55. Connect to vehicle using Toolbox 3.0
  56. Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
  57. 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
    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
    ’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    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
  58. Inspect coolant level and top off as necessary
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    Note
    Ensure that the fluid level is at the Max line
  59. Install coolant bottle cap
  60. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  61. Close hood
  62. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  63. Raise LH front window
  64. Close LH front door
  65. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  66. Check tire pressures
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    Note
    4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar
  67. Verify the alignment slip/turn plates are locked
  68. Drive vehicle onto alignment rack
  69. Pull vehicle forward and stop ~ 0.5 ft before turn plates to allow for rolling compensation
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    Note
    Shift to park
  70. Shift to park
  71. Install wheel chocks
    Informational PurposesAn informational icon, calling your attention
    Note
    Place chocks on both sides of the driver's side rear tire
  72. Latch the driver seat belt to buckle
  73. Latch LH front door and place vehicle into neutral
    Informational PurposesAn informational icon, calling your attention
    Note
    Careful not to slam the door while latch is engaged
  74. Raise alignment rack partially and lower to lock position
  75. Install alignment heads onto wheels
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    Note
    4x alignment heads
  76. Enter vehicle information to alignment machine
  77. Perform rolling compensation
    Informational PurposesAn informational icon, calling your attention
    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
  78. Unlock alignment slip/turn plates
  79. Verify chassis height measurement tool is calibrated
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    Note
    Adjust if necessary, Measure height of tool and adjust reading to match
  80. Perform ride height measurement
    Informational PurposesAn informational icon, calling your attention
    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
  81. Apply brake pedal depressor
  82. Perform caster sweep and install steering wheel holder and level tool
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    Note
    If camber and caster are out of specification, perform necessary camber and caster adjustment
  83. Verify alignment reading is within specification and print vehicle summary
  84. Remove alignment heads from wheels
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    Note
    4x alignment heads
  85. Remove brake pedal depressor
  86. Lock alignment slip/turn plates
  87. Lower the alignment rack to ground
  88. Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
  89. Unlatch LH front seat belt
  90. Remove wheel chocks
  91. Remove vehicle from alignment rack