02/04/2024 00:58:33

Mount - Clevis - Front Drive Unit - LH (Remove and Replace)

Correction Code 39014302

  • 2024-03-01: Updated procedure to latest validation: no need to remove/install the HV battery.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1081765-00-A 3/4 TON UNDERHOIST STAND
Tesla 1056566-00-A 5MM LOCATING SHIM SET FOR FRONT DU REPLACEMENT
Tesla 1083188-00-B MULTIMETER
Tesla 1032900-01-A HEAT INDUCTOR TOOL (EMEA)
Tesla 1032900-00-A TOOL, INDUCTIVE HEATING (NA, APAC)
Tesla 1134264-00-A DRIVE UNIT OIL DRAIN KIT
1096075-00-A HYDRAULIC HUB PULLER
1498673-00-A CABLE AXLE REMOVAL KIT
1083189-00-A ATF OIL REFILLER

Removal

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Loosen the wheel lug nuts (x5).
  3. Loosen the LH front axle nut.
  4. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  5. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  6. Disconnect 12V power. See Disconnect 12V Power.
  7. Remove the 12V battery bracket. See Bracket - 12V Battery (Dual Motor) (Remove and Replace).
  8. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  9. Remove the bolts (x2) that attach the front bash plate extrusion to the vehicle.
  10. Remove the front bash plate stamping. See Bash Plate - Front - Stamping (Remove and Replace).
  11. Remove and discard the front HV battery bolts (x4).
  12. Remove the skid plate from between the HV battery and the front subframe.
  13. Disconnect the rear battery coolant pump connector.
  14. Release the clip that attaches the rear battery coolant pump hose to the subframe.
  15. Release the clip that attaches the HVAC drain hose to the rear battery coolant pump hose.
  16. Release the rear battery coolant pump from the bracket.
  17. Move the rear battery coolant pump away for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slightly pull down on the coolant pump to gain access to the RH FDU acoustic cover.
  18. Gain access to the FDU drain plug.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x Velcro straps. Unfasten the Velcro straps on the RH FDU acoustic cover and move it to gain access to the drain plug.
  19. Place an oil drain container under the FDU.
  20. Drain the oil from the FDU.
  21. Reinstall the FDU drain plug (torque 28 Nm).
  22. Spray the area with brake cleaner and wipe residual fluid off with a towel.
  23. Install RH FDU acoustic cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x Velcro straps. Reach around the LH side of the drive unit to fasten the rear Velcro strap.
  24. Install the rear battery coolant pump onto the mounting bracket.
  25. Install the clip that attaches the HVAC drain hose to the rear battery coolant pump hose.
  26. Install the clip that attaches the rear battery coolant pump hose to the subframe.
  27. Connect the rear battery coolant pump connector.
  28. Release the LH front air spring module from the front lower aft link.
  29. Release the LH stabilizer end link from the stabilizer and move it away from the stabilizer bar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Counter hold the stud with a 5 mm hex socket and use a wrench to remove the Nyloc nut. Discard the nut after removal.
  30. Remove the LH front wheel. See Wheel Assembly (Remove and Install).
  31. Remove the LH front axle nut and washer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the nut after removal.
  32. Install the hub puller onto the LH front brake rotor.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, hand tight.
  33. Use the hub puller to remove the LH halfshaft from the hub splines.
  34. Remove the hub puller from the brake rotor.
  35. Release the LH front wheel speed sensor grommet from knuckle.
  36. Remove and discard the nut that attaches the LH front wheel speed sensor bracket to the body.
  37. Remove and discard the nut that attaches the LH knuckle to the upper control arm ball joint.
  38. Disconnect the LH knuckle from the upper control arm.
    Informational PurposesAn informational icon, calling your attention
    Note
    While holding the upper control arm to ball joint, slide bolt out of top of knuckle. This will release the knuckle from the upper control arm ball joint. Support the knuckle as the ball joint is released.
  39. Remove and discard the LH tie rod nut and move the tie rod end away.
  40. Remove the LH halfshaft from the LH hub assembly.
  41. Remove the LH halfshaft from the FDU and remove it from the vehicle.
    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 the U-bolt. Use a slide hammer with cable eyelets to release. Take care not to damage the halfshaft boots and oil seals.
  42. Support the FDU with a pole jack.
  43. Release the clevis from the LH front rail.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the bolts and washers after removal.
  44. Remove and discard the bolts (x2) that attach the clevis to the FDU.

Installation

  1. Put the new clevis mount into position.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts with washers, 2x bolts with nutplate. Install the clevis mount with the straight side towards the rear. Install new bolts, torque at a later step.
  2. Install the shim kit onto the RH motor mount.
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the Jack if alignment shims do not slide into place easily.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    While adjusting the jack, shims may fall off
  3. Torque the bolts that attach the clevis to the LH front rail (torque 65 Nm).
  4. Check fitment of shims.
    Informational PurposesAn informational icon, calling your attention
    Note
    If alignment shims do not slide into place easily, loosen the clevis mount bolts and repeat the torque steps.
  5. Torque the bolts that attach the clevis to the FDU (torque 50 Nm)
  6. Check for fitment of the shims.
    Informational PurposesAn informational icon, calling your attention
    Note
    If alignment shims do not slide into place easily, loosen the clevis mount bolts and repeat torque steps.
  7. Remove the shims.
  8. Remove the transmission jack from under the vehicle.
  9. Apply Molykote M-77 to the outboard side of LH front halfshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean, if necessary. Apply no more than 1 gram to the axle only.
  10. Install the LH front halfshaft into the hub and bearing assembly and install the nut and washer hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at a later step. Use the nut without the washer to pull the shaft through the hub. Then, remove nut and install the washer and nut. Do not use power tools, the risk of stripping the threads is very high.
  11. Install the bolt and nut that attach the LH front air spring module to the front lower aft link (torque 140 Nm).
  12. Install the LH knuckle to the upper control arm.
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat the upper control arm ball joint into the knuckle and slide the bolt through the knuckle to hold it in place. The bolt should slide through the knuckle towards the front of the vehicle on installation. The bolt head should be at the rear of the knuckle.
  13. Install the nut that attaches the LH upper control arm ball joint to the LH front knuckle (torque 60 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install a new patch nut.
  14. Install a new Nyloc nut that attaches the LH stabilizer end link to the stabilizer bar (torque 70 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Counter hold stud with a 5 mm hex socket.
  15. Install a new Nyloc nut that attaches the front tie rod to the LH front knuckle (torque 103 Nm).
  16. Install the nut that attaches the LH front wheel speed sensor bracket to the body (torque 4 Nm).
  17. Install the LH front wheel speed sensor grommet to the knuckle.
  18. Install the LH front wheel. See Wheel (Remove and Replace).
  19. Install the skid plate between the HV battery and the front subframe.
  20. Install new front HV battery bolts (x4, torque 30 Nm).
  21. Install the bolts (x2) that attach the bash plate lower stamping (torque 9 Nm).
  22. Install new patch bolts (x2) that attach the front lower bash plate extrusion (16 Nm).
  23. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  24. Torque the LH front wheel lug nuts to 175 Nm.
  25. Torque the LH front axle nut to 245 Nm.
  26. Install lug nut covers and LH front wheel center cap
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that the center cap emblem is aligned with the valve stem.
  27. Remove the FDU fill plug.
  28. Fill the FDU with oil.
    Informational PurposesAn informational icon, calling your attention
    Note
    Informational PurposesAn informational icon, calling your attention
    Note
    See Fluids for oil types and for oil quantities based on front drive unit type.
  29. Install the FDU fill plug (torque 28 Nm).
  30. Install the 12V battery bracket. See Bracket - 12V Battery (Dual Motor) (Remove and Replace).
  31. Install the 12V battery tray onto the 12V battery bracket.
  32. Install the 12V battery to the vehicle. See Battery - Auxiliary - 12V (Remove and Replace).
  33. Connect 12V power. See Disconnect 12V Power.
  34. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  35. Install the HEPA filter outlet duct and all parts that were removed for removal of the outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).