2025-04-29

Hydraulic Control Unit (HCU) - Brake (Non-Structural Pack) (Remove and Replace)

Correction code 33109522 2.16 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.

  • 2025-04-29: Corrected torque figures for the bolts that attach the shock tower brace to the vehicle.
  • 2023-12-05: Updated brake stiffness routine.
  • 2023-07-21: Removed Jack Mode note.
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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.
  1. Raise and support vehicle
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    Note
    Ensure vehicle is not charging before lifting it off the ground,
  2. Open LH front door
  3. Lower LH front window
  4. Lock steering wheel into position
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    Note
    Protect seat from damage
  5. Remove the 12V battery. See 12V/LV Battery (Remove and Replace).
  6. Remove the inner bolts that attach the shock tower brace to the RH shock tower.
  7. Remove the outer bolt that attaches the shock tower brace to the RH shock tower.
  8. Remove the inner bolts that attach the shock tower brace to the LH shock tower.
  9. Remove the outer bolt that attaches the shock tower brace to the LH shock tower.
  10. Shift shock tower brace assembly to gain clearance for removal of battery bracket
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    Note
    Shift shock tower brace forward, but do not fully remove
  11. Remove bolt securing the steering gear assembly to intermediate shaft assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 18 Nm
  12. Slide the electric steering column upward to remove it from the steering gear assembly
  13. Remove all four wheels. See Wheel Assembly (Remove and Install).
  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 outer fasteners from front aero shield
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    Note
    7x bolts, 10mm, 5 Nm
  16. Remove remaining nuts and remove front aero shield from vehicle
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    Note
    2x nuts, 15mm, 5 Nm
  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. Disconnect the hydraulic control unit connector
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    Note
    1x connector, Disengage locking tab and pull up on connector to release
  19. Position the oil drain container under hydraulic control unit area
  20. Remove the RH front brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  21. Remove the LH rear brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  22. Remove the RH rear brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  23. Remove the LH front brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  24. Remove the master cylinder secondary pipe nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  25. Remove the master cylinder primary pipe nut from hydraulic control unit
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    Note
    1x nut, 12mm, 16 Nm
  26. Remove the master cylinder brake lines from the 4 tube bundle
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    Note
    1x clip
  27. Remove RH front brake line from front brake line bundle clip around the LH front rail area
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    Note
    1x brake line
  28. Move brake lines away from hydraulic control unit
  29. Release the master cylinder brake lines from clip at rear of hydraulic control unit bracket
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    Note
    1x harness clip
  30. Remove the oil drain container from underneath vehicle
  31. 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
  32. Remove the bolts securing the hydraulic control unit to frame rail
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    Note
    2x bolts, 10mm, 10 Nm
  33. Remove the hydraulic control unit and bracket from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Slide the HCU toward 12V battery area to remove
  34. Loosen the fasteners securing the hydraulic control unit to the hydraulic control unit bracket
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    Note
    2x nuts, 10mm, 8 Nm
  35. Pry hydraulic control unit from the bracket
  36. Install hydraulic control unit into hydraulic control unit bracket
  37. Install the fasteners securing hydraulic control unit to the hydraulic control unit bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 8 Nm
  38. Position the hydraulic control unit and bracket into vehicle for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Align hydraulic control unit bracket datums into body
  39. Install the bolts securing the hydraulic control unit to frame rail
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  40. 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
  41. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm
  42. Position the front aero shield to vehicle and install nuts
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    Note
    2x nuts, 15mm, 5 Nm
  43. 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
  44. Position the master cylinder brake lines to clip at rear of hydraulic control unit bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  45. Install RH front brake line to front brake line bundle clip around the LH front rail area
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    Note
    1x brake line
  46. Install the master cylinder brake lines to 4 tube bundle clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  47. Install the master cylinder primary pipe nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  48. Install the master cylinder secondary pipe nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  49. Move master cylinder lines into position for installation
  50. Install the LH front brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  51. Install the RH rear brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  52. Install the LH rear brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  53. Install the RH front brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  54. Connect the hydraulic control unit connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Gently push connector downward, Engage locking tab
  55. Slide the intermediate shaft assembly downward to install it to the steering gear assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
  56. Install bolt securing the intermediate shaft assembly to the steering gear assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 18 Nm
  57. Position shock tower brace assembly back for installation
  58. Install the outer bolt that attaches the shock tower brace to the LH shock tower.
  59. Install the inner bolts (x2) that attach the shock tower brace to the LH shock tower.
  60. Tighten the outer bolt that attaches the shock tower brace to the RH shock tower.
  61. Tighten the inner bolts (x2) that attach the shock tower brace to the RH shock tower.
  62. Install the 12V battery. See 12V/LV Battery (Remove and Replace).
  63. Remove the steering wheel holder
  64. Connect to vehicle using Toolbox 3.0
  65. Select ‘Actions/Autodiag’ and search for ‘Service_Redeploy’
  66. Select ‘UPDATE_CAN-REDEPLOYvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
    • chassis ➜ DPB Post Replacement ➜ CAN Redeploy
    • chassis ➜ ESP Post Replacement ➜ CAN Redeploy
    • chassis ➜ IDB Post Replacement ➜ CAN Redeploy
    • chassis ➜ RCU Post Replacement ➜ CAN Redeploy
    • chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
    • chassis ➜ IBST Replacement Panel ➜ CAN Redeploy
    ’, click ‘Run’, and allow routine to complete
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    Note
    Select ‘X’ at top right of window to close once complete
  67. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  68. Once firmware redeploy is complete, Verify on center display release notes are present
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    Note
    If the redeploy fails you may receive an error message on UI
  69. Bleed the brakes. See Brake Fluid Bleed/Flush.
  70. Install all four wheels. See Wheel Assembly (Remove and Install).
  71. Remove vehicle from lift
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    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  72. Raise LH front window
  73. Close LH front door
  74. Perform test drive
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    Note
    Per current FRT (00040100) 0.3 hrs, If alignment was adjusted verify tracking, If DAS components were adjusted verify operation, If brakes were serviced perform burnishing