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.
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.
-
Raise and support vehicle
NoteEnsure vehicle is not charging before lifting it off the ground,
- Open LH front door
- Lower LH front window
-
Lock steering wheel into position
NoteProtect seat from damage
- Remove the 12V battery. See 12V/LV Battery (Remove and Replace).
- Remove the inner bolts that attach the shock tower brace to the RH shock tower.
- Remove the outer bolt that attaches the shock tower brace to the RH shock tower.
- Remove the inner bolts that attach the shock tower brace to the LH shock tower.
- Remove the outer bolt that attaches the shock tower brace to the LH shock tower.
-
Shift shock tower brace assembly to gain
clearance for removal of battery bracket
NoteShift shock tower brace forward, but do not fully remove
-
Remove bolt securing the steering gear
assembly to intermediate shaft assembly
Note1x bolt, 13mm, 18 Nm
- Slide the electric steering column upward to remove it from the steering gear assembly
- Remove all four wheels. See Wheel Assembly (Remove and Install).
-
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 outer fasteners from front aero
shield
Note7x bolts, 10mm, 5 Nm
-
Remove remaining nuts and remove front
aero shield from vehicle
Note2x nuts, 15mm, 5 Nm
-
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
-
Disconnect the hydraulic control unit
connector
Note1x connector, Disengage locking tab and pull up on connector to release
- Position the oil drain container under hydraulic control unit area
-
Remove the RH front brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the LH rear brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the RH rear brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the LH front brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the master cylinder secondary
pipe nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the master cylinder primary pipe
nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the master cylinder brake lines
from the 4 tube bundle
Note1x clip
-
Remove RH front brake line from front
brake line bundle clip around the LH front rail area
Note1x brake line
- Move brake lines away from hydraulic control unit
-
Release the master cylinder brake lines
from clip at rear of hydraulic control unit bracket
Note1x harness clip
- Remove the oil drain container from underneath vehicle
-
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 the bolts securing the hydraulic
control unit to frame rail
Note2x bolts, 10mm, 10 Nm
-
Remove the hydraulic control unit and
bracket from vehicle
Note2x tabs, Slide the HCU toward 12V battery area to remove
-
Loosen the fasteners securing the
hydraulic control unit to the hydraulic control unit bracket
Note2x nuts, 10mm, 8 Nm
- Pry hydraulic control unit from the bracket
- Install hydraulic control unit into hydraulic control unit bracket
-
Install the fasteners securing hydraulic
control unit to the hydraulic control unit bracket
Note2x nuts, 10mm, 8 Nm
-
Position the hydraulic control unit and
bracket into vehicle for installation
Note2x tabs, Align hydraulic control unit bracket datums into body
-
Install the bolts securing the hydraulic
control unit to frame rail
Note2x bolts, 10mm, 10 Nm
-
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
-
Apply Loctite 222 onto front aero shield
bolts and install outer fasteners to front aero shield
Note7x bolts, 10mm, 5 Nm
-
Position the front aero shield to
vehicle and install nuts
Note2x nuts, 15mm, 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
-
Position the master cylinder brake lines
to clip at rear of hydraulic control unit bracket
Note1x harness clip
-
Install RH front brake line to front
brake line bundle clip around the LH front rail area
Note1x brake line
-
Install the master cylinder brake lines
to 4 tube bundle clip
Note1x clip
-
Install the master cylinder primary pipe
nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the master cylinder secondary
pipe nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
- Move master cylinder lines into position for installation
-
Install the LH front brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the RH rear brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the LH rear brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the RH front brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Connect the hydraulic control unit
connector
Note1x connector, Gently push connector downward, Engage locking tab
-
Slide the intermediate shaft assembly
downward to install it to the steering gear assembly
NoteEnsure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
-
Install bolt securing the intermediate
shaft assembly to the steering gear assembly
Note1x bolt, 13mm, 18 Nm
- Position shock tower brace assembly back for installation
- Install the outer bolt that attaches the shock tower brace to the LH shock tower.
- Install the inner bolts (x2) that attach the shock tower brace to the LH shock tower.
- Tighten the outer bolt that attaches the shock tower brace to the RH shock tower.
- Tighten the inner bolts (x2) that attach the shock tower brace to the RH shock tower.
- Install the 12V battery. See 12V/LV Battery (Remove and Replace).
- Remove the steering wheel holder
- Connect to vehicle using Toolbox 3.0
- Select ‘Actions/Autodiag’ and search for ‘Service_Redeploy’
-
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
NoteSelect ‘X’ at top right of window to close once complete - Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
-
Once firmware redeploy is complete,
Verify on center display release notes are present
NoteIf the redeploy fails you may receive an error message on UI
- Bleed the brakes. See Brake Fluid Bleed/Flush.
- Install all four wheels. See Wheel Assembly (Remove and Install).
-
Remove vehicle from lift
NoteLower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
- Raise LH front window
- Close LH front door
-
Perform test drive
NotePer 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