Mount - Front Drive Unit - RH (2nd Generation) - Remove and Replace: Removal

This procedure is for vehicles built after April 24, 2019. For vehicles built through April 24, 2019, see Mount - Front Drive Unit - RH (1st Generation) - Remove And Replace .

1. Verify there is no abnormal tire wear per Courtesy Inspection
   NOTE: SC-14-00-001 Standard Courtesy Inspection Checklist, While performing courtesy inspection, Note any abnormal tire wear that could indicate the need for an alignment

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2. Set up A/C machine and perform hose flush
   NOTE: Touch time only

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3. Open all four doors

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4. Lower all four windows

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5. Raise and support vehicle
   NOTE: Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads

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6. Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 3
   NOTE: 1x connector, 2x clips, Remove cubby under MCU and connect laptop to vehicle, Open Toolbox 3 website and establish connection to 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), Local connection will enable service mode plus on display

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7. Unlock vehicle Gateway
   NOTE: After vehicle has been put into "Service Mode", hold down the brake pedal, while holding down break pedal simultaneously hold the turn signal stalk fully up for at least 10 seconds, "GTW UNLOCKING" should pop up on the instrument cluster right below the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 899" will be displayed on the instrument cluster underneath the VIN, the gateway will remain unlocked for 15 minutes, follow steps on Toolbox article #5582900 for any additional information

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8. Select 'Actions' tab and search for 'PROC_THC_X_FLUID-FILL-DRAIN'

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9. Select Action 'Start', Fluid Fill Target 'Refrigerant' and press 'Run'
   NOTE: Check the Routine's Notes before pressing Run, Verify successfully "Passed'

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10. Wait to see that the routine 'Passed' successfully
    NOTE:

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11. Install steering wheel lock to ensure proper placement of the steering wheel

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12. Move RH front seat fully forward

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13. Open hood
    NOTE: Via Controls > Front Trunk

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14. Remove rear underhood apron
    NOTE: 8x clips

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15. Remove RH underhood apron
    NOTE: 9x clips

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16. Remove LH underhood apron
    NOTE: 9x clips

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17. Remove front underhood apron
    NOTE: 7x clips

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18. Release drainage hoses from HEPA filter inlet duct
    NOTE: 2x hoses

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19. Remove clips securing HEPA filter inlet duct to cowl panel
    NOTE: 3x push clips

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20. Remove HEPA filter inlet duct
    NOTE: 2x clips on HEPA filter

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21. Remove HEPA filter outlet duct from vehicle
    NOTE: Lift up, pull towards front of vehicle, then rotate clockwise

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22. Remove dust caps from high-side and low-side service ports
    NOTE: 2x caps

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23. Connect hoses to vehicle and perform A/C recovery
    NOTE: Touch time only, Ensure quick connects are fully engaged, Turn the connector dials clockwise to fully connect to A/C service ports

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24. Disconnect light and release switch connectors and remove underhood storage carpet
    NOTE: 2x connectors, Release edge of carpet from underneath underhood storage unit seal

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25. Remove bolts and clips securing underhood storage unit
    NOTE: 2x bolts, 10 mm, 7 N.m, 2x push clips

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26. Push wiring harness grommet through underhood storage unit and remove underhood storage unit
    NOTE: 1x grommet, Lift the underhood storage unit appropriately to access the grommet

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27. Power off vehicle via UI
    NOTE: Via Controls > Safety > Power Off

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28. Disconnect 12V negative terminal and First Responder Loop
    NOTE: 1x nut, 10 mm, 5 N.m, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components

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29. Remove 2nd row seat bottom cushion
    NOTE: 2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side

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30. Remove NVH padding from underneath 2nd row seat cushion
    NOTE: If equipped

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31. Remove bolts securing seat bottom frame
    NOTE: 8x bolts, 11 mm, 26 N.m

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32. Lift up and support seat bottom frame
    NOTE: 8x clips

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33. Remove tamper evident label from charger cover panel

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34. Remove all items from pockets and ensure not wearing metal items
35. Inspect HV insulating gloves
    NOTE: Check gloves for damage prior to use, Refer to Tech Note 15-92-003 , for information on inspecting HV gloves.

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36. Put on HV insulating gloves and leather over gloves

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37. Release HV charger access panel cover
    NOTE: 11x bolts, T20, 2 N.m, Discard after removal

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38. Release tabs and open both access doors
    NOTE: 4x tabs, Make sure to wear proper PPE

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39. Verify no high voltage
    NOTE: Measure B+ to B-, B+ to ground, and B- to ground, Make sure to wear proper PPE, Verify you are using a proper ground and not a coated surface, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work escalate a toolbox session for assistance

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40. Secure HV charger access panel cover
    NOTE: 11x bolts, T20, 2 N.m, Install new patch bolts

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41. Remove HV insulating gloves

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42. Install new warranty label onto charger cover panel
    NOTE: Wipe charger with IPA prior to installation, Allow 1 minute for IPA to dry

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43. Lower seat frame into position and secure harness clips to frame
    NOTE: 8x clips

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44. Install and torque bolts securing seat frame to vehicle
    NOTE: 8x bolts, 11 mm, 26 N.m

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45. Place NVH padding onto seat frame

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46. Install seat bottom cushion
    NOTE: 2x clips, 7x connectors if equipped, Replace clips if necessary

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47. Remove A/C lines from vehicle
    NOTE: Press clear lines once lines have been removed

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48. Release chiller assembly from front subframe
    NOTE: 3x bolts, 10 mm, 5 N.m

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49. Slide battery pump 2 off of the bracket secured to subframe
    NOTE: Slide pump to the right of vehicle for removal

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50. Disconnect steering rack connectors
    NOTE: 2x connectors, 2 stage locking connectors, Disengage the red locking tab before disconnecting

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51. Disconnect the logic connectors for the steering rack
    NOTE: 2x electrical connectors, 2-way connectors, slide the grey lock out, then depress the lock to disconnect

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52. Release logic connector harness from subframe
    NOTE: 1x fir tree clip

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53. Remove the fasteners securing air suspension pump bracket to subframe
    NOTE: 2x bolts, 10 mm, 5.5 N.m

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54. Secure air suspension pump bracket and chiller assembly to front end carrier
    NOTE: Use bungee cord or something similar to hold assemblies in general position

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55. Remove accessible bolt on RH 3-way valve
    NOTE: 1x bolt, T30, 5 N.m, Remaining bolt will be removed at later step

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56. Remove 12V positive terminal cover
    NOTE: 2x tabs

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57. Disconnect 12V positive terminal
    NOTE: 1x nut, 10 mm, 6 N.m

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58. Remove fasteners securing 12V battery bracket to shock tower cross member and the battery beam
    NOTE: 2x bolts, T30, 5 N.m, 2x bolts, 13 mm, 15 N.m

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59. Remove 12V battery bracket assembly
    NOTE: 2x clips

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60. Remove fastener securing coolant hose to battery beam
    NOTE: 1x bolt, T30, 5 N.m

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61. Remove fasteners securing the battery beam to the LH and RH body beams
    NOTE: 2x bolts, T30, 3.5 N.m, 1x edge clip

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62. Remove the battery beam

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63. Disconnect coolant reservoir level sensor
    NOTE: 1x connector

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64. Disconnect AC compressor logic connector
    NOTE: 1x connector

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65. Release ground connection at the A/C compressor mount bracket
    NOTE: 1x bolt, T25, 7 N.m

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66. Remove AC lines from compressor
    NOTE: 2x nuts, 10 mm, 10 N.m, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

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67. Release ground strap from front drive unit
    NOTE: 1x bolt, E10, 6 N.m

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68. Disconnect logic connector from front drive unit
    NOTE: 1x connector with lock tab

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69. Remove lug nut covers from LH front wheel
    NOTE: 5x covers

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70. Remove lug nut covers from RH front wheel
    NOTE: 5x covers

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71. Remove RH front wheel center cap
    NOTE: 1x cap

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72. Remove LH front wheel center cap
    NOTE: 1x cap

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73. Loosen LH front axle nut
    NOTE: 1x nut, 32 mm, 245 N.m

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74. Loosen RH front axle nut
    NOTE: Note 1x nut, 32 mm, 245 N.m

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75. Loosen RH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m

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76. Loosen LH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m

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77. Raise vehicle partially and lower onto locks
    NOTE: Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side

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78. Remove LH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m

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79. Remove LH tie rod nut and move tie rod end away
    NOTE: 1x Nyloc nut, 21 mm, 103 N.m, Discard after removal

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80. Remove RH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m

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81. Remove RH tie rod nut and move tie rod end away
    NOTE: 1x Nyloc nut, 21 mm, 103 N.m, Discard after removal

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82. Remove nuts and bolts securing RH front wheel arch liner
    NOTE: 2x nuts, 10 mm, 4 N.m, 3x bolts, 10 mm, 4 N.m

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83. Remove clips securing RH front wheel arch liner
    NOTE: 7x push clips

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84. Release clips and remove RH front wheel arch liner from vehicle
    NOTE: 3x clips

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85. 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

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86. Remove clips securing LH shear plate to wheel fairing
    NOTE: 2x push clips

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87. Remove LH shear plate
    NOTE: 2x clips, 1x nyloc nut, 15 mm, 35 N.m, 3x screws, T25, 6 N.m, 1x bolt, 10 mm, 4 N.m, Discard nyloc nut after removal

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88. Remove clips securing RH shear plate to wheel fairing
    NOTE: 2x push clips

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89. Remove RH shear plate
    NOTE: 2x clips, 1x nyloc nut, 15 mm, 35 N.m, 3x screws, T25, 6 N.m, 1x bolt, 10 mm, 4 N.m, Discard nyloc nut after removal

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90. Remove bolts securing mid aero shield to vehicle
    NOTE: 7x bolts, 10 mm, 4 N.m

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91. Remove clips securing mid aero shield to vehicle
    NOTE: 7x push clips

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92. Remove mid aero shield from vehicle

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93. Remove front bash plate extrusion
    NOTE: 2x bolts, T30, 16 N.m

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94. Remove LH ski side covers
    NOTE: 14x push clips, 3x covers

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95. Remove RH ski side covers
    NOTE: 14x push clips, 3x covers

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96. Remove four center bolts securing HV battery
    NOTE: 4x patch bolts, E12, 38 N.m, Discard after removal

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97. Position battery table beneath vehicle

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98. Lower vehicle to table
    NOTE: Recommend assistance, Align table to vehicle and raise casters to level table if necessary

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99. Remove remaining eight center bolts securing HV battery
    NOTE: 8x patch bolts, E12, 38 N.m, Discard after removal

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100. Remove front four HV battery bolts
     NOTE: 4x patch bolts, 13 mm, 30 N.m, Discard after removal

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101. Remove 21 mm bolts securing front of HV battery
     NOTE: 2x bolts, 21 mm, 115 N.m, Discard after removal

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102. Remove LH rocker bolts
     NOTE: 8x patch bolts, 13 mm, 55 N.m, Discard after removal

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103. Remove RH rocker bolts
     NOTE: 8x patch bolts, 13 mm, 55 N.m, Discard after removal

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104. Raise vehicle off HV battery

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105. Move battery away from vehicle

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106. Remove all items from pockets and ensure not wearing metal items
107. Inspect HV insulating gloves
     NOTE: Check gloves for damage prior to use, Refer to Tech Note 15-92-003 , for information on inspecting HV gloves.

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108. Put on HV insulating gloves and leather over gloves

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109. Verify no high voltage at HV rapid mate
     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

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110. Install HV and LV Rapid Mate covers
     NOTE: 2x covers, If covers not available then use masking tape to protect Rapid Mate from debris

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111. Remove HV insulating gloves
112. Remove clips securing front aero shield to vehicle
     NOTE: 10x push clips

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113. Remove bolts securing front aero shield to vehicle and remove
     NOTE: 12x bolts, 10 mm, 4 N.m

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114. Remove skid bar from front subframe
     NOTE: 4x bolts, 10 mm, 10 N.m

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115. Remove the bolts securing the bash plate stamping and skid plate to the front subframe skid plate
     NOTE: 2x bolts, 10 mm, 9 N.m

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116. Remove skid plate from front subframe
     NOTE: 2x bolts, 10 mm, 9 N.m

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117. Remove nut and bolt securing RH front air spring module to front lower aft link
     NOTE: 1x bolt, 21 mm, 1x nut, 21 mm, 140 N.m, Use pry bar to release tension from air spring module to control arm

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118. Remove nut and bolt securing LH front air spring module to front lower aft link
     NOTE: 1x bolt, 21 mm, 1x nut, 21 mm, 140 N.m

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119. Remove the fasteners securing the LH front lower aft link to the subframe and move the aft link aside
     NOTE: 1x bolt, 21 mm, 1x nut, 22 mm, 130 N.m, Index the location of the eccentric with a paint marker

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120. Remove the fasteners securing the LH front lower fore link to the subframe and move the fore link aside
     NOTE: 1x bolt, 21 mm, 1x nut, 22 mm, 130 N.m, Index the location of the eccentric with a paint marker

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121. Remove the fasteners securing the RH front lower aft link to the subframe and move the aft link aside
     NOTE: 1x bolt, 21 mm, 1x nut, 22 mm, 130 N.m, Index the location of the eccentric with a paint marker

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122. Remove the fasteners securing the RH front lower fore link to the subframe and move the fore link aside
     NOTE: 1x bolt, 21 mm, 1x nut, 22 mm, 130 N.m, Index the location of the eccentric with a paint marker

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123. Remove LH stabar nut from the stabar and move LH stabar end link away from the bar
     NOTE: 1x nyloc nut, 15 mm, 70 N.m, Counter hold stud with 5 mm hex socket and use wrench to remove nut, Discard after removal

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124. Remove RH stabar nut from the stabar and move RH stabar end link away from the bar
     NOTE: 1x nyloc nut, 15 mm, 70 N.m, Counter hold stud with 5 mm hex socket and use wrench to remove nut, Discard after removal

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125. Remove the bolt securing the lower i-shaft to the steering gear and slide the i-shaft up away from the steering gear
     NOTE: 1x bolt, 13 mm, 30 N.m

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126. Remove forward bolt securing RH 3-way valve to subframe bracket
     NOTE: 1x bolts, T30, 5 N.m

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127. Remove the LH stay bar
     NOTE: 2x bolts, 10 mm, 11 N.m

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128. Remove the RH stay bar
     NOTE: 2x bolts, 10 mm, 11 N.m

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129. Remove nuts holding ABS pump to subframe and release from rubber grommet
     NOTE: 2x nuts, 10 mm, 9 N.m, 1 rubber grommet

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130. Position coolant drain container under the front of the vehicle to catch vehicle coolant

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131. Disconnect FDU inlet hose and plug both openings
     NOTE: 1x hose clip, 1x fir tree clip

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132. Disconnect the hose from the battery coolant heater to coolant pump 2 at the rear of the subframe and plug the ends
     NOTE: 1x hose clamp, 3x fir tree clips, Make sure to remove hose from between steering rack and subframe

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133. Move coolant drain container below right side of FDU

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134. Disconnect coolant hose from radiator inlet and plug the open connections
     NOTE: 1x hose clip, 1x fir tree clip

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135. Remove coolant drain container from underneath vehicle

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136. Remove the fasteners securing the FJB to FDU HV harness to the FJB
     NOTE: 4x bolts, T30, 7 N.m, Discard bolts after removal

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137. Disconnect AC HV cable from front junction box
     NOTE: 1x connector, 2 stage locking connectors

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138. Position the powertrain table with the Model S/Model X subframe adapter installed under the front of the vehicle

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139. Connect shop air supply to the powertrain table

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140. Raise the powertrain table and subframe fixture into position
     NOTE: Ensure the pins are installed into the correct positions on the fixture, Ensure the pins engage the subframe so it is properly supported

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141. Remove the bolts that secure the front subframe to the bumper carrier
     NOTE: 4x patch bolts, 10 mm, 7.5 N.m, Discard after removal

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142. Remove the fastener connecting the LH stabar mount to the body through the subframe
     NOTE: 1x bolt, 16 mm, 80 N.m

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143. Remove the fastener connecting the RH stabar mount to the body through the subframe
     NOTE: 1x bolt, 16 mm, 80 N.m

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144. Remove the LH rear bolt securing the front subframe to the body
     NOTE: 1x bolt, 18 mm, 115 N.m

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145. Remove the RH rear bolt securing the front subframe to the body
     NOTE: 1x bolt, 18 mm, 115 N.m

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146. Lower the front subframe, and move the assembly from under the vehicle
     NOTE: The powertrain table will need to be tilted with rear side angled down and front side tilted up as the subframe is clearing front end carrier, Take caution not to damage front end carrier

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147. 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

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148. Remove LH front axle nut and washer
     NOTE: 1x nut, 32 mm, 245 N.m, Discard after removal

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149. Install hub puller onto the LH front brake rotor
     NOTE: 5x lug nuts, 21 mm, Hand tight

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150. Use hub puller to free LH halfshaft from hub splines
     NOTE: Counter hold hub adapter

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151. Remove hub puller from LH hub assembly
     NOTE: 5x lug nuts, Hand tight

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152. Remove LH halfshaft from LH hub assembly
     NOTE: Adjust hub puller if further clearance is needed to free shaft from knuckle

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153. Install the axle removal tool around the inner joint of the LH front halfshaft
     NOTE: Use a wire tie to hold the axle removal tool in place

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154. Remove LH front halfshaft from the drive unit and remove from the vehicle

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155. Remove axle nut and washer securing RH drive axle to hub assembly
     NOTE: 1x nut, 32 mm, 245 N.m

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156. Install the hub puller onto the RH front brake rotor
     NOTE: 5x lug nuts, 21 mm, Hand tight

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157. Use hub puller to free RH halfshaft from hub splines
     NOTE: Counter hold hub adapter

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158. Remove hub puller from RH hub assembly

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159. Remove RH halfshaft from RH hub assembly
     NOTE: Adjust hub puller if further clearance is needed to free shaft from knuckle

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160. Install the axle removal tool around the inner joint of the RH front halfshaft
     NOTE: Use a wire tie to hold the axle removal tool in place

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161. Remove RH front halfshaft from the drive unit and remove from the vehicle

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162. Position transmission jack fixture under drive unit
     NOTE: Secure FDU strap

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163. Remove bolts from LH FDU mount to body
     NOTE: 2x bolts, E14, 65 N.m

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164. Remove bolts securing RH FDU mount to body
     NOTE: 2x bolts, EP20, 120 N.m

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165. Lower front drive unit with jack out of vehicle

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166. Remove the bolts (x4) that attach the RH side mount onto the front drive unit, and then remove t he mount from the drive unit.

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