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Home >> Tesla >> 2019 >> Model X Long Range >> Repair and Diagnosis (Single Page) >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Front Drive Unit -- Model X >> Front Drive Unit Assembly >> Drive Unit - Front (1st Generation) - Remove And Install >> Installation

Drive Unit - Front (1st Generation) - Remove And Install: Installation

  1. Raise the front drive unit into the vehicle.
    CAUTION: Make sure that components are not caught on the front drive unit as it is being installed.
  2. If required, attach the shear plate.
    NOTE: Drive units with part number of 1035000-01-J or later do not require shear plates, and require 4 patchbolts (part number 1078944-00-B or later). Drive units with part number of 1035000-00-J or earlier require shear plates, and require 4 patchbolts (part number of 1050057-00-B or later).
    1. Insert and align the shear plate.
      CAUTION: Install the shear plate on the TRA (torque reaction arm) facing the subframe, do not install the shear plate between the motor housing and the TRA
      WARNING: Support the shear plate while you insert and finger-tighten the first two bolts. If only one bolt is inserted, the shear plate might rotate downward quickly and strike someone or a part of the vehicle.
      G15207362Courtesy of TESLA, INC.
    2. Install and finger-tighten the bolts (x4) that attach the shear plate and RH front drive unit mount to the front drive unit.
  3. Install and finger-tighten the bolts (x3) that attach the front drive unit to the LH mount.
    CAUTION: Replace all patchbolt(s).
  4. Use the shim tools to make sure there is sufficient clearance between the RH front drive unit mount and the body.
    1. Position the shim tools as follows:
      G15207363Courtesy of TESLA, INC.
      1  2-pronged shim tool. Working from the underhood area, position the 2-pronged shim around the RH front drive unit mount front bushing.
      G15207364Courtesy of TESLA, INC.
      2  Hook shim tool. Reach beneath the front drive unit and position the hook shim tool between the mount and outer bushing.
      3  Straight shim tool. Reach downward between the V-brace and cross brace and position the straight shim tool between the mount and inner bushing.
      NOTE: Leave the shim tolls in place until prompted to remove, after all front drive unit mount bolts are fully torqued.
    2. Attach the 15 mm low profile socket to the torque + angle wrench.
    3. Set the torque + angle wrench to a torque value of 35 N.m.
  5. Torque the bolts.
    1. Torque the bolts (x4) to the RH front drive unit mount (torque 35 N.m) in the sequence shown:
      Fig 1: RH Front Drive Unit Mount Bolts With Torque Tightening Sequence (1 Of 2)
      G15207365Courtesy of TESLA, INC.
      Fig 2: RH Front Drive Unit Mount Bolts With Torque Tightening Sequence (2 Of 2)
      G15207366Courtesy of TESLA, INC.
    2. Set the torque + angle wrench to the correct angle value. For vehicles with a front drive unit with a part number of:
      • 1035000-01-J or later, set the torque angle to 55 degrees.
        G15207367Courtesy of TESLA, INC.
      • 1035000-00-J or earlier, set the torque angle to 75 degrees.
        G15207368Courtesy of TESLA, INC.
    3. Torque the bolts to the specified angle in the sequence shown:
      Fig 3: RH Front Drive Unit Mount Bolts With Angle Tightening Sequence (1 Of 2)
      G15207369Courtesy of TESLA, INC.
      Fig 4: RH Front Drive Unit Mount Bolts With Angle Tightening Sequence (2 Of 2)
      G15207370Courtesy of TESLA, INC.
    4. Torque the bolts (x3) that attach the front drive unit to the LH front drive unit mount (torque 38 N.m).
    5. Remove the shim tools, then attempt to reinstall them:
      • If all 3 shim tools can be easily installed and removed, the front drive unit is properly positioned.
      • If the shim tools can not be easily installed and removed, loosen all LH and RH front drive unit mount bolts and repeat step  1 through step  5.
  6. Install the bolts (x2) that attach the LH front drive unit mount to the side rail (torque 65 N.m).
    G15207371Courtesy of TESLA, INC.
  7. Lower the transmission jack.
  8. Remove the transmission jack from underneath the vehicle.
  9. Remove the front drive unit cradle from the transmission jack.
    G15207372Courtesy of TESLA, INC.
  10. Install the lower RH acoustic cover onto the front drive unit.
  11. CAUTION: When the drive unit was replaced by a new or remanufactured unit, before installing the LH halfshaft make sure to complete the checks on the LH output seal as described in the Installation section of DRIVE UNIT - FRONT (1ST GENERATION) (REMOVE AND REPLACE) .

    Install the LH halfshaft into the LH hub.

  12. Align the LH halfshaft so that the opening in the snap ring is down, facing towards the bottom of the front drive unit.
  13. Insert the LH halfshaft into the front drive unit.
    NOTE: Do not damage or displace the oil seal.
  14. Carefully push the LH halfshaft into the front drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
    NOTE: There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
  15. Pull on the LH inner halfshaft cup to confirm that the LH halfshaft circlip is locked into place.
    NOTE: If the halfshaft detaches from the front drive unit, repeat from step  12 and then test that the halftshaft is fully seated.
    G15207373Courtesy of TESLA, INC.
  16. Install the LH axle nut.
  17. Install the jackshaft to the front drive unit, and then install the bolts (x2) that attach the jackshaft to the front drive unit (torque 30 N.m).
    G15207374Courtesy of TESLA, INC.
  18. Install the RH halfshaft into the RH hub.
  19. Align the jackshaft so that the opening in the snap ring is down, facing towards the bottom of the front drive unit.
  20. Insert the RH halfshaft onto the jack shaft.
    NOTE: Do not damage or displace the oil seal.
    G15207375Courtesy of TESLA, INC.
  21. Carefully push the RH halfshaft onto the jack shaft until there is an audible "click" from the jackshaft.
    NOTE: There will be a slight pulling sensation on the halfshaft as the jackshaft circlip locks into place.
  22. Pull on the RH inner halfshaft cup to confirm that the jackshaft circlip is locked into place.
    NOTE: If the halfshaft detaches from the jackshaft, repeat from step  19 and then test that the halftshaft is fully seated.
  23. Install the RH axle nut.
  24. Refill the drive unit with gearbox fluid. See GEARBOX FLUID - FRONT DRIVE UNIT (1ST GENERATION) (DRAIN AND REFILL) .
  25. Install the acoustic padding onto the front drive unit.
  26. Return the chiller and coolant pump from the RH side of the working area to near the front drive unit.
  27. Connect the coolant hose between the chiller and battery coolant pump 2, and then release the clamp from the hose.
  28. Install battery coolant pump 2 onto the bracket on the chassis.
    G15207376Courtesy of TESLA, INC.
  29. Install the front subframe assembly. See SUBFRAME ASSEMBLY - FRONT - 1ST GENERATION (REMOVE AND INSTALL) .
  30. Carefully inspect the connector seals of the HV cables. If any are damaged, replace them.
  31. Apply P-80 emulsion to the connector seals of the HV cables.
    CAUTION: Do not apply P-80 emulsion to the HV terminals.
    G15207377Courtesy of TESLA, INC.
  32. Insert the HV cables into the LH side of the front drive unit, and then install the upper screws (x2) that attach the HV cables to the front drive unit (torque 7 N.m).
    G15207378Courtesy of TESLA, INC.
  33. Install the lower screws (x2) that attach the HV cables to the LH side of the front drive unit (torque 7 N.m).
    G15207379Courtesy of TESLA, INC.
  34. Return powertrain coolant pump 2 to the LH side of the front drive unit.
  35. Connect the coolant hoses to the powertrain coolant pump 2, and then release the clamp from the hoses.
  36. Install powertrain coolant pump 2 onto the bracket.
    G15207380Courtesy of TESLA, INC.
  37. Raise the vehicle to a working height.
  38. Connect the electrical harness to the front drive unit low voltage connector.
    NOTE: Make the connection, then slide the red locking tab into the connector.
    G15207381Courtesy of TESLA, INC.
  39. Install the ground strap to the stud on the left side of the body, and then tighten the nut that attaches the ground strap to the body (torque 9 N.m).
    G15207382Courtesy of TESLA, INC.
  40. Connect the front drive unit coolant hoses to the front and LH side of the front drive unit, and then release the clamps from the hoses.
    G15207383Courtesy of TESLA, INC.
  41. With the help of an assistant, install the A/C compressor to the front drive unit, and then install the bolts (x3) that attach the A/C compressor bracket to the front drive unit (torque 10 N.m).
    NOTE: Do not spill any oil from the compressor. If oil spills from the compressor, the system might experience a failure due to inadequate lubrication after reinstallation.
    G15207384Courtesy of TESLA, INC.
  42. Insert the A/C lines into the compressor, and then install the nuts (x2) that attach the A/C lines to the compressor (torque 5.5 N.m).
    G15207385Courtesy of TESLA, INC.
  43. Connect the electrical harness to the compressor low voltage connector.
    G15207386Courtesy of TESLA, INC.
  44. Position the ground strap to the compressor bracket, and then install the screw that attaches the ground strap to the compressor bracket (torque 8 N.m).
    G15207387Courtesy of TESLA, INC.
  45. Connect the compressor HV harness to the forward junction box.
    G15207388Courtesy of TESLA, INC.
  46. Carefully return the coolant reservoir from the LH side of the vehicle, remove the plug from the coolant hole, and install the coolant hose at the rear of the coolant reservoir.
    G15207389Courtesy of TESLA, INC.
  47. Release the clamp from the coolant hose.
    G15207390Courtesy of TESLA, INC.
  48. Connect the electrical harness to the coolant reservoir coolant level sensor connector.
  49. Install the coolant reservoir to the front crossmember, and then install the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 N.m).
  50. Install the 12V battery cage. See CAGE - BATTERY - AUXILIARY - 12V (REMOVE AND REPLACE) .
  51. Install the HV Battery. See HV BATTERY (AWD) (REMOVE AND INSTALL) .
  52. Install the LH front wheel arch liner. See WHEEL ARCH LINER - FRONT - LH (REMOVE AND REPLACE) .
  53. Install the front wheels. See WHEEL (REMOVE AND INSTALL) .
  54. Torque the axle nuts.
  55. Install the center caps onto the front wheels.
  56. Install the cowl screen panel. See PANEL - COWL SCREEN (REMOVE AND REPLACE) .
  57. Install the HEPA filter duct. See DUCT - HEPA FILTER (REMOVE AND REPLACE) .
  58. Refill and bleed the cooling system. See COOLING SYSTEM - DRAIN AND REFILL .
  59. Recharge the A/C refrigerant. See A/C REFRIGERANT RECOVERY AND RECHARGE (REMOVE AND REPLACE) .
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