Steering Rack (RHD Dual Motor) (3rd Generation) (Remove and Replace)

Open RH front door

Lower front windows

Open hood

Note

Using MCU touchscreen > Controls > Frunk Trunk

Place air suspension into "Jack Mode"

Note

Controls > Suspension > Jack mode

Center steering wheel and install steering wheel holder

Open hood

Note

Using MCU touchscreen > Controls > Frunk Trunk

Remove rear underhood apron

Note

8x clips

Remove LH underhood apron

Note

9x clips

Remove RH underhood apron

Note

9x clips

Release drainage hoses from HEPA filter inlet duct

Note

2x hoses

Remove clips securing HEPA filter inlet duct to cowl panel

Note

3x push clips

Remove HEPA filter inlet duct

Note

2x clips on HEPA filter

Remove HEPA filter outlet duct from vehicle

Note

Lift up, pull towards front of vehicle, then rotate clockwise

Raise and support vehicle

Note

Set air suspension to "Jack Mode" if equipped Via Controls > ''Service''

Power down vehicle using MCU

Note

Controls > Safety&Security > Power Off > ''POWER OFF''

Disconnect 12V negative terminal and First Responder Loop

Note

1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components

Disconnect light and release switch connectors and remove underhood storage carpet

Note

2x connectors, Release edge of carpet from underneath underhood storage unit seal

Remove underhood storage unit

Note

2x bolts, 10mm, 7 Nm, 2x push clips

Push wiring harness grommet through underhood storage unit and remove

Note

1x grommet

Remove lug nut covers from LH front wheel

Note

5x covers

Loosen LH front wheel

Note

5x nuts, 21mm, 175 Nm

Remove lug nut covers from RH front wheel

Note

5x covers

Loosen RH front wheel

Note

5x nuts, 21mm, 175 Nm

Raise vehicle partially and lower 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 LH front wheel

Note

5x nuts, 21mm, 175 Nm

Remove RH front wheel

Note

5x nuts, 21mm, 175 Nm

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 clips securing LH shear plate to wheel fairing

Note

2x push clips

Remove LH shear plate

Note

1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal

Remove clips securing RH shear plate to wheel fairing

Note

2x push clips

Remove RH shear plate

Note

1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal

Remove clips securing mid aero shield to vehicle

Note

7x push clips

Remove bolts securing mid aero shield to vehicle

Note

7x bolts, 10mm, 4 Nm

Remove ski side covers on RH side

Note

14x clips, 3x covers

Remove ski side covers on LH side

Note

14x clips, 3x covers

Remove front lower bash plate extrusion

Note

2x bolts, T30, 16 Nm

Remove four center bolts securing HV battery

Note

4x patch bolts, E12, 38 Nm, Discard after removal

Position battery table beneath vehicle

Lower vehicle to table

Note

Recommend assistance, Align table to vehicle and raise casters to level table if necessary

Remove remaining eight center bolts securing HV battery

Note

8x patch bolts, E12, 38 Nm, Discard after removal

Remove front four HV battery bolts

Note

4x patch bolts, 13mm, 30 Nm, Discard after removal

Remove 21mm bolts securing front of HV battery

Note

2x bolts, 21mm, 115 Nm, Discard after removal

Remove LH rocker bolts

Note

8x patch bolts, 13mm, 55 Nm, Discard after removal

Remove RH rocker bolts

Note

8x patch bolts, 13mm, 55 Nm, Discard after removal

Raise vehicle off of HV battery

Move battery away from vehicle

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, for information on inspecting HV gloves, https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

Put on HV insulating gloves and leather over gloves

Check voltage on HV rapid mate

Note

B+ to ground, B- to ground, and B+ to B-, If any voltage reading is more than 10V, the pack contactors are not fully opened, Contact Engineering for support

Cover the high voltage connector with a HV Rapid Mate cover, and the low voltage connector with a LV Rapid Mate cover

Note

If these covers are not available, cover the Rapid Mate connectors with masking tape to prevent debris from falling in

Remove clips securing front aero shield to vehicle

Note

10x push clips

Remove bolts securing front aero shield to vehicle and remove

Note

12x bolts, 10mm, 4 Nm

Remove the bolts securing the bash plate stamping and skid plate to the front subframe skid plate

Note

2x bolts, 10mm, 9 Nm

Remove clip that secures the coolant pump 2 hose to the subframe

Note

1x clip

Remove PT coolant pump 2 harness clip from front subframe

Note

1x clip

Slide PT coolant pump 2 from front subframe

Remove the LH stay bar

Note

2x bolts, 10mm, 11 Nm

Remove the RH stay bar

Note

2x bolts, 10mm, 11 Nm

Remove skid bar from front subframe

Note

4x bolts, 10mm, 10 Nm

Remove nuts holding ABS pump to subframe and release from rubber grommet

Note

2x nuts, 10mm, 9 Nm, 1 rubber grommet

Remove forward bolt securing RH 3-way valve to subframe bracket

Note

1x bolts, T30, 5 Nm

Lower vehicle partially and set lift onto locks

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height

Remove bolts for chiller to subframe

Note

3x bolts, 10mm, 5 Nm

Slide coolant pump 1 off of the subframe bracket

Note

Note: the coolant hose is still between subframe and sway bar

Disconnect steering rack connectors

Note

2x connectors

Remove the fasteners securing air suspension pump bracket to subframe

Note

2x bolts, 10mm, 5.5 Nm

Remove accessible bolt on RH 3-way valve

Note

1x bolt, T30, 5 Nm, Remaining bolt will be removed at later step

Install a bar across frame rails and support removed accessories

Raise vehicle partially and lower 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

Loosen the LH tie rod end jam nut

Note

1x nut, 21mm, 70 Nm

Remove the LH nut that secures the tie rod end to the knuckle and disconnect tie rod from knuckle

Note

1x nyloc nut, 21mm, 103 Nm, Discard after removal

Loosen the RH tie rod end jam nut

Note

1x nut, 21mm, 70 Nm

Remove the nut that secures the tie rod end to the RH knuckle

Note

1x nut, 21mm, 103 Nm, Prevent ball joint damage from spinning by holding the ball joint pin with counter force to the nut, Discard after removal

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 LH stabar nut from the stabar and move LH stabar end link away from the bar

Note

1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal

Remove RH stabar nut from the stabar and move RH stabar end link away from the bar

Note

1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal

Remove the bolt and nut that secure the LH front shock absorber to the rear lower control arm

Note

1x nut, 21mm, 1x bolt, 21mm, 140 Nm

Remove the bolt and nut that secure the RH front shock absorber to the rear lower control arm

Note

1x nut, 21mm, 1x bolt, 21mm, 140 Nm

Remove LH side lower control arm nuts

Note

2x nyloc nuts, 21mm, 196 Nm, 2x washers, Discard after removal, Need to hold ball joint to prevent damage

Remove RH side lower control arm nuts

Note

2x nyloc nuts, 21mm, 196 Nm, 2x washers, Discard after removal, Need to hold ball joint to prevent damage

Remove the bolt that secures the lower intermediate shaft to the steering rack and slide the shaft off of the rack

Note

1x bolt, 13mm, 49 Nm

Remove the bolts that secure the front subframe to the bumper carrier

Note

4x patch bolts, 10mm, 7.5 Nm, Discard after removal

Position subframe fixture beneath vehicle and raise fixture

Remove the bolts that secure the subframe to the chassis

Note

2x bolts, 18mm , 115 Nm, 2x bolts, 16mm, 115 Nm,

Lower subframe and move it away from vehicle

Note

Need to tilt subframe back to remove from carrier, Be mindful of coolant hoses and chiller, may need to feed them past the sway bar

Remove LH tie rod end

Note

Count the number of turns and remember for install

Remove RH tie rod end

Note

Count the number of turns and remember for install

Remove steering rack from subframe

Note

3x bolts, 21mm, 175 Nm,

Install steering rack with new bolts

Note

3x bolts, 21mm, 175 Nm

Install RH tie rod end and snug the jam nut

Note

Remember how many turns to put back on

Install LH tie rod end and snug the jam nut

Note

Remember how many turns to put back on

Install subframe in position for install

Note

Need to tilt subframe back to install into the carrier, Be mindful of coolant hoses and chiller, may need to feed them past the sway bar

Install the bolts that secure the subframe to the chassis

Note

2x bolts, 18mm, 115 Nm, 2x bolts, 16mm, 115 Nm

Remove subframe fixture from under vehicle

Install the bolts that secure the front subframe to the bumper carrier

Note

4x patch bolts, 10mm, 7.5 Nm, Install new bolts

Install the bolt that attaches the lower intermediate shaft to the steering rack.

Note

1x bolt, 13mm, 30 Nm

Install RH side lower control arm nuts

Note

2x nyloc nuts and washers, 21mm, 196 Nm, Install new nuts and washers, Need to hold ball joint to prevent damage

Install LH side lower control arm nuts

Note

2x nyloc nuts and washers, 21mm, 196 Nm, Install new nuts and washers, Need to hold ball joint to prevent damage

Install new nut that secures the RH sway bar to the sway bar end links

Note

1x nyloc nut, 15mm, 70 Nm, Install new nuts

Install nut securing LH stabar end link to stabar

Note

1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket

Loosely install the bolt and nut that secure the RH front shock absorber to the rear lower control arm

Note

1x nut, 21mm, 1x bolt, 21mm, 140 Nm, Torqued at a later step

Loosely install the bolt and nut that secure the LH front shock absorber to the rear lower control arm

Note

1x nut, 21mm, 1x bolt, 21mm, 140 Nm, Torqued at a later step

Install forward bolt of RH 3-way coolant valve

Note

1x bolts, T30, 5 Nm

Install ABS pump to subframe

Note

2x nuts, 10mm, 9 Nm

Install skid bar onto the front subframe

Note

4x bolts, 10mm, 10 Nm

Install RH stay bar

Note

2x bolts, 10mm, 11 Nm

Install LH stay bar

Note

2x bolts, 10mm, 11 Nm

Slide PT coolant pump 2 to front subframe

Install PT coolant pump 2 harness clip to front subframe

Note

1x clip

Install clip that secures coolant pump 2 hose to the subframe

Note

1x clip

Install the bolts securing the bash plate stamping and skid plate to the front subframe skid plate

Note

2x bolts, 10mm, 9 Nm

Lower vehicle partially and set lift onto locks

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height

Install nut securing RH front tie rod end to RH front knuckle

Note

1x nyloc nut, 21mm, 103 Nm, Install new nut

Install nut securing LH front tie rod end to LH front knuckle

Note

1x nyloc nut, 21mm, 103 Nm, Install new nut

Lower vehicle partially and set lift onto locks

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height

Remove the bar across frame rails

Install remaining fastener securing RH 3-way valve to subframe

Note

1x bolt, T30, 5 Nm

Install the fasteners securing air suspension pump bracket to subframe

Note

2x bolts, 10mm, 5.5 Nm

Connect steering rack connectors

Note

2x connectors

Slide coolant pump 1 on to the subframe bracket

Note

1x coolant pump

Install the chiller to the subframe

Note

3x bolts, 10mm, 5 Nm

Raise vehicle fully and lower 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, Ensure the vehicle is stable by rocking the vehicle on the lift immediately after the tires have left the ground, Always lower the lift arms onto the locks after raising the vehicle

Install front aero shield into position and hand tighten center bolts

Note

2x bolts, 10mm, 4 Nm

Install clips securing aero shield to vehicle

Note

10x push clips

Install and tighten bolts securing aero shield to vehicle

Note

4x bolts, 10mm, 4 Nm, Outer bolts will be installed with wheel arch liners

Position HV battery underneath vehicle

Remove covers or tape from LV and HV rapid mates

Lower vehicle onto pack

Note

Align rapid mate connections before lowering fully, Recommend assistance

Loosely install 4 new front bolts for HV battery

Note

4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Torque at later step

Loosely install LH rocker bolts

Note

8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Torque at later step

Loosely install RH rocker bolts

Note

8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Torque at later step

Loosely install 21mm bolts at front of HV battery hand tight

Note

2x bolts, 21mm, 115 Nm, Install new bolts, Torque at later step

Loosely install eight outer center bolts hand tight

Note

8x patch bolts, E12, 38 Nm, Install new patch bolts, Torque at later step

Torque rocker HV battery bolts on both sides

Note

16x patch bolts, 13mm, 55 Nm

Torque remaining HV battery bolts

Note

8x patch bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x patch bolts, 13mm, 30 Nm

Raise vehicle and remove battery table

Note

Recommend assistance

Install front lower bash plate extrusion

Note

2x patch bolts, T30, 16 Nm

Install ski side covers onto RH side of HV battery

Note

14x clips, 3x covers

Install ski side covers onto LH side of HV battery

Note

14x clips, 3x covers

Lower vehicle partially and set lift onto locks

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height

Install LH front wheel

Note

5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool

Install RH front wheel

Note

5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool

Lower vehicle until tires are touching the ground

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Torque LH front wheel

Note

5x nuts, 21mm, 175 Nm

Torque RH front wheel

Note

5x nuts, 21mm, 175 Nm

Install RH front lug nut covers

Note

5x covers

Install LH front lug nut covers

Note

5x covers

Connect First Responder Loop and 12V negative terminal

Note

1x connector, 1x nut, 10mm, 5 Nm

Install underhood storage unit

Note

Install harness and grommet

Install bolts and clips securing underhood storage unit

Note

2x bolts, 10mm, 7 Nm, 2x push clips

Install underhood storage carpet and reconnect light and release switch connectors

Note

2x connectors, Secure edges of carpet underneath underhood storage unit seal

Install HEPA filter outlet duct

Install HEPA filter inlet duct

Note

2x tabs, One on each side

Install clips securing HEPA filter inlet duct to cowl panel

Note

3x push clips

Secure drainage hoses to HEPA filter inlet duct

Note

2x hoses

Install RH underhood apron

Note

9x clips

Install LH underhood apron

Note

9x clips

Install rear underhood apron

Note

8x clips

Close hood

Note

Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood

Lower vehicle and remove from lift

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Remove air suspension from "Jack Mode" if equipped

Remove steering holder from vehicle

Perform a lock to lock angle test. See Lock To Lock-Angle Test.

Perform a firmware update. See Firmware Update.

Position vehicle onto 4-post lift

Note

Set ride height to standard

Torque LH air spring module nut and bolt to LH aft link

Note

1x bolt, 21mm, 1x nut, 22mm, 140 Nm

Remove existing paint mark from LH air spring module bolt

Note

Clean the area thoroughly so the new marking is not confused with the previous marking

Mark LH air spring module bolt to show component has been torqued

Note

Use a high visibility paint pen when marking components

Torque RH air spring module nut and bolt to RH aft link

Note

1x bolt, 21mm, 1x nut, 22mm, 140 Nm

Remove the existing paint mark from RH air spring module

Note

Clean the area thoroughly so the new marking is not confused with the previous marking

Mark the RH air spring module bolt to show the component has been torqued

Note

Use a high visibility paint pen when marking components

Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.

Perform a test drive.

Note

Per current FRT 00040100 (0.3)

Model S Service Manual

Steering Rack (RHD Dual Motor) (3rd Generation) (Remove and Replace)

Figure 1

Figure 2

Figure 3