01/04/2024 13:56:58

Brake Lines - Rear - RH to Sill (Structural Pack) (Remove and Replace)

Correction code 33035312 2.76 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.

2024-01-26: Corrected High Voltage check sequence.
2023-12-08: Updated brake stiffness routine.

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

Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
Remove butyl patches covering LH rocker access holes

Note
2x butyl patches, Clean excess butyl from area
Install lift pad adapters onto LH rocker

Note
2x lift pad adapters
Remove the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
Remove butyl patches covering RH rocker access holes

Note
2x butyl patches, Clean excess butyl from area
Install lift pad adapters onto RH rocker

Note
2x lift pad adapters
Raise and support vehicle

Note
Verify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
Open LH front door
Lower LH front window
Open hood
Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Remove bolt securing frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Release washer tank neck from washer tank and set aside

Note
1x O-ring, No need to remove hose from neck
Remove HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
Remove all four wheels. See Wheel Assembly (Remove and Install).
Remove the LH rear wheel arch liner. See Wheel Arch Liner - Rear - LH (Structural Pack) (Remove and Replace).
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 push clips at left and right wheel house liner to mid aero shield

Note
2x clips
Remove mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will have one less bolt and one extra clip
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Install amp clamp to RDU HV harness

Note
Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
Release RDU HV harness from HV battery

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Verify no high voltage at RDU HV header

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Position coolant drain container underneath LH rear of HV battery
Remove clip securing RDU inverter inlet hose to RDU HV cable

Note
1x clip
Disconnect RDU inverter inlet hose from fluid coupling

Note
1x spring clip, 2x plugs, Plug ends as needed
Remove RDU inverter inlet hose

Note
1x spring clip, 1x clip, Rotate between subframe and battery out of vehicle
Release RDU oil cooler outlet pipe

Note
2x spring clips, 5x clips, Plug hose connections as needed
Remove RDU oil cooler outlet pipe

Note
Rotate down over RDU and rearward around subframe
Remove coolant drain container from underneath vehicle
Remove RDU 12V harness clip

Note
1x clip
Disconnect RDU 12V connector

Note
1x connector
Remove bolt securing RDU HV cable bracket to RDU

Note
1x bolt, 10mm, 6 Nm
Disconnect RDU HV cable from RDU

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up
Remove RDU HV cable from vehicle

Note
Carefully route cable out and do damage housing or surrounding components
Remove smaller fasteners for LH and RH shear plates

Note
4x bolts, 13mm, 47 Nm, Bolt position 8-9 and 14-15
Loosen large bolt securing LH shear plate and subframe to body and rotate shear plate clear of HV battery

Note
1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
Loosen large bolt securing RH shear plate and subframe to body and rotate shear plate clear of HV battery

Note
1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
Remove nut securing LH 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 LH 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 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
Position support stand to support front portion of rear subframe
Remove bolts securing stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Discard after removal
Lower support stand and remove stabilizer bar from vehicle
Release RH rear brake line from LH rear junction block

Note
1x nut, 12mm, 16 Nm
Release RH rear brake line from jounce hose

Note
1x nut, 12mm, 16 Nm
Release RH rear brake line from clips

Note
8x clips, Do not bend pipe
Position support stand to support front portion of rear subframe

Note
Rear stabilizer bar should not be installed at this point
Remove large fore bolts securing rear subframe to body and lower support stand

Note
2x fore bolts, 21mm, 130 Nm, Lower subframe just enough for RH rear pipe to pass through
Remove RH rear brake line

Note
Do not bend pipe, Four-step removal, Guide LH side of pipe over subframe bushing, Guide RH side of pipe over top of subframe, Guide LH side of pipe between battery and subframe gap then rotate to RH side of vehicle, Guide RH side of pipe over subframe bushing

Install

Install RH rear brake line

Note
Do not bend pipe, Four-step installation, Guide RH side of pipe over subframe bushing, Rotate RH side of pipe to LH side of vehicle and guide between battery and subframe gap, Guide RH side of pipe over top of subframe, Guide LH side of pipe over subframe bushing
Raise support stand and install large fore bolts securing rear subframe to body hand tight

Note
2x fore bolts, 21mm, 130 Nm, Make sure RH rear pipe does not get pinched between subframe and body, Torque at later step
Remove support stand from front portion of rear subframe

Note
Rear stabilizer bar should not be installed at this point
Secure RH rear brake line onto clips

Note
8x clips, Do not bend pipe
Secure RH rear brake line onto jounce hose

Note
1x nut, 12mm, 16 Nm
Secure RH rear brake line onto LH rear junction block

Note
1x nut, 12mm, 16 Nm
Place stabilizer bar into position for installation and raise stand to support stabilizer bar
Install bolts securing stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Install new patch bolts
Position LH 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 LH 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
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
Remove support stand from under vehicle
Loosen RH rear subframe bolt and align RH rear shear plate with HV battery

Note
1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 62 Nm, Bolt position 8-9, Torque at later step
Torque bolt securing subframe and RH rear shear plate to body

Note
1x bolt, 21mm, 130 Nm
Torque small fasteners securing RH rear shear plate to body

Note
2x bolts, 13mm, 62 Nm, Bolt position 8-9
Loosen LH rear subframe bolt and align LH rear shear plate with HV battery

Note
1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
Install bolts securing LH rear shear plate to body hand tight

Note
2x bolts, 13mm, 62 Nm, Bolt position 14-15, Torque at later step
Torque bolt securing subframe and LH rear shear plate to body

Note
1x bolt, 21mm, 130 Nm
Torque small fasteners securing LH rear shear plate to body

Note
2x bolts, 13mm, 62 Nm, Bolt position 14-15
Position RDU HV cable into vehicle

Note
Carefully maneuver cable in and do damage housing or surrounding components
Connect RDU HV cable onto RDU

Note
1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
Install bolt securing RDU HV cable bracket to RDU

Note
1x bolt, 10mm, 6 Nm
Secure RDU HV harness onto HV battery

Note
1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
Install RDU 12V connector

Note
1x connector
Install RDU 12V harness clip

Note
1x clip
Position coolant drain container underneath LH rear of HV battery
Install RDU oil cooler outlet pipe

Note
Rotate up over RDU and rearward around subframe to oil cooler
Secure RDU oil cooler outlet pipe

Note
2x spring clips, 5x clips, Remove plugs as needed
Install RDU inverter inlet hose

Note
1x spring clip, 1x clip, Rotate between subframe and battery into RDU and PCS outlet, Remove plugs as needed
Remove hose plugs and connect coolant inlet hose to rear drive unit

Note
1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
Remove coolant drain container from underneath vehicle
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
Install push clips at left and right wheel house liner to mid aero shield

Note
2x clips
Lower vehicle for access to underhood area

Note
Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Connect first responder loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Remove coolant bottle cap
Fill coolant to the proper level

Note
Ensure that the fluid level filled to the Max line
Fill brake bleeder reservoir to full level
Clean area around brake fluid reservoir and remove brake reservoir cap
Top off brake fluid reservoir

Note
Top off brake fluid as needed
Install pressure bleeder adapter onto reservoir
Set brake bleed reservoir pressure to 30 psi

Note
Connect power supply to bleeder and turn on the power, Set pressure to 30 psi, Attach brake bleed reservoir to brake bleed adapter
Connect to vehicle using Toolbox 3.0

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)
Select Actions/Autodiag and search for "bleed"
Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open LH front brake caliper outer bleeding valve then click the play button next to "PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Repeat the above step till clear fluid and no air bubbles come out of the LH front brake caliper bleeding valve

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers

Note
2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open RH front brake caliper outer bleeding valve then Click the play button next to "PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers

Note
2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open RH rear brake caliper bleeding valve then Click the play button next to "PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover

Note
1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open LH rear brake caliper bleeding valve then Click the play button next to "PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED" and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Repeat the above step untill clear fluid and no air bubbles come out of the LH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover

Note
1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
Remove pressure bleeder adapter from reservoir
Check fluid level

Note
Top off if necessary
Install brake reservoir cap
Pump the brake pedal a few times to ensure the brake pedal feels normal
Using Toolbox 3:
1. Select the Actions tab and search for "Stiffness".
2. Select the ODIN routine IBST Stiffness Test - Service - BURNISHED/UNBURNISHEDTEST_BRAKE_X_STIFFNESS-TEST-SERVICEGen3/tasks/TEST_BRAKE_X_STIFFNESS-TEST-SERVICEChassisChassis / Brakes - Brake Stiffness TestService Mode Service Plus Factory Mode Developer , and then click the link of the routine.
3. If brake pads or rotors have been replaced, select UNBURNISHED under "Action_Type". In all other cases, select BURNISHED.
4. Click RUN, and allow the routine to complete.
  
  Note
  Do not press the brake pedal during the test.
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, Speeds can be monitored in garage under PT Thermal tab, 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
Install coolant bottle cap
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Remove ethernet cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
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
Install the LH rear wheel arch liner. See Wheel Arch Liner - Rear - LH (Structural Pack) (Remove and Replace).
Install all four wheels. See Wheel Assembly (Remove and Install).
Install HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
Install washer tank neck to washer tank

Note
1x O-ring, Ensure washer hose is properly routed after installation
Secure frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Close hood
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle
Raise LH front window
Close LH front door
Remove lift pad adapters from LH rocker

Note
2x lift pad adapters
Install butyl patches onto LH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
Install the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
Remove lift pad adapters from RH rocker

Note
2x lift pad adapters
Install butyl patches onto RH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
Install the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).