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Home >> Tesla >> 2021 >> Model Y Performance >> Repair and Diagnosis (Single Page) >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Front Drive Unit -- Model Y >> Front Drive Unit Assembly >> Bushing - Front Drive Unit - RH - Remove And Replace >> Removal and Replace

Removal and Replace

  1. Vehicle preparation
    NOTE: Ensure vehicle is not charging before the repair
  2. Open all four doors
    NOTE: Open LH front door
  3. Lower LH front window
  4. Move LH front seat forward
  5. Move RH front seat forward
  6. Release 2nd row seat cushion
    NOTE: Lift front edge of seat cushion upward to release foam from frame, Pull towards front of vehicle then tilt bench against 40/60 back
    G14843629Courtesy of TESLA, INC.
  7. Move LH front seat backward
    G14843630Courtesy of TESLA, INC.
  8. Set steering wheel straight ahead
  9. Lock steering wheel into position
    NOTE: Protect seat from damage
    G14843631Courtesy of TESLA, INC.
  10. Open hood
  11. Remove rear apron
    NOTE: 14x clips
    G14843632Courtesy of TESLA, INC.
    G14843633Courtesy of TESLA, INC.
  12. Remove access panel
    NOTE: 3x clips, 1x connector
    G14843634Courtesy of TESLA, INC.
    G14843635Courtesy of TESLA, INC.
  13. Remove fasteners securing the frunk assembly
    NOTE: 5x bolts, 10 mm, 5 N.m, Newer vehicles may be equipped with 1x push clip securing frunk to reservoir neck
    G14843636Courtesy of TESLA, INC.
    G14843637Courtesy of TESLA, INC.
  14. Remove frunk assembly from vehicle
    NOTE: 6x clips, Replace any clips if broken or missing
    G14843638Courtesy of TESLA, INC.
  15. Remove fasteners holding upper portion of front fascia to vehicle
    NOTE: 5x bolts, 10 mm, 4 N.m
    G14843639Courtesy of TESLA, INC.
  16. Remove bolt securing the steering gear assembly to intermediate shaft assembly
    NOTE: 1x bolt, 13 mm, 18 N.m
    G14843640Courtesy of TESLA, INC.
  17. Slide the electric steering column upward to remove it from the steering gear assembly
    G14843641Courtesy of TESLA, INC.
  18. Power off vehicle from center display
    NOTE: Via Controls > Safety & Security > Vehicle Power > Power Off
  19. Disconnect 12V negative terminal and first responders loop
    NOTE: 1x nut, 10 mm, 6 N.m, 1x connector. Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V. Negative terminal should be disconnected before FRL. Allow 2 minutes for all electrical circuits to fully discharge
    G14843642Courtesy of TESLA, INC.
    G14843643Courtesy of TESLA, INC.
  20. Disconnect the steering gear assembly connectors
    NOTE: 2x connectors. Two stage connectors. Slide red locking tab to unlock, then depress the connector release to disconnect
    G14843644Courtesy of TESLA, INC.
  21. Remove all items from pockets and ensure not wearing metal items
    G14843645Courtesy of TESLA, INC.
    G14843646Courtesy of TESLA, INC.
  22. Inspect HV insulating gloves
    NOTE: Check gloves for damage prior to use. Refer to Tech Note TN-15-92-003 , "High Voltage Awareness Care Points" for information on inspecting HV gloves.
    G14843647Courtesy of TESLA, INC.
  23. Put on HV insulating gloves and leather over gloves
    NOTE: Make sure to wear Electrical Protective Gloves any time Hioki tester is used
    G14843648Courtesy of TESLA, INC.
  24. Remove the bolts securing penthouse probe lid cover to penthouse cover
    NOTE: 2x bolts, EP10 5-Lobe, 6 N.m. Discard after removal
    G14843649Courtesy of TESLA, INC.
  25. Remove the penthouse probe lid cover from the penthouse cover
    G14843650Courtesy of TESLA, INC.
  26. Verify no high voltage
    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
    G14843651Courtesy of TESLA, INC.
    G14843652Courtesy of TESLA, INC.
    G14843653Courtesy of TESLA, INC.
    G14843654Courtesy of TESLA, INC.
  27. Position the penthouse probe lid cover to the penthouse cover
    NOTE: Inspect gasket to confirm it has no visual damage
    G14843655Courtesy of TESLA, INC.
    G14843656Courtesy of TESLA, INC.
  28. Install the bolts securing penthouse probe lid cover to penthouse cover
    NOTE: 2x bolts. EP10 5-Lobe, 6 N.m, Install new rubber washer bolts
    G14843657Courtesy of TESLA, INC.
  29. Remove HV insulating gloves
  30. 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
  31. Remove outer fasteners from front aero shield
    NOTE: 7x bolts, 10 mm, 5 N.m
    G14843658Courtesy of TESLA, INC.
  32. Remove remaining nuts and remove front aero shield from vehicle
    NOTE: 2x nuts, 15 mm, 5 N.m
    G14843659Courtesy of TESLA, INC.
  33. Release LH front wheel liner from HV battery
    NOTE: 1x clip, 1x bolt, 10 mm, 5 N.m
    G14843660Courtesy of TESLA, INC.
  34. Release RH front wheel liner from HV battery
    NOTE: 1x clip, 1x bolt, 10 mm, 5 N.m
    G14843661Courtesy of TESLA, INC.
  35. 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
  36. Remove LH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m
  37. Remove LH front fender garnish
    NOTE: 11x clips, 1x push clip, 3x tabs. Release from center of garnish and work your way outward towards both ends. Be cautious not to bend front tabs going into front fascia
    G14843662Courtesy of TESLA, INC.
    G14843663Courtesy of TESLA, INC.
    G14843664Courtesy of TESLA, INC.
    G14843665Courtesy of TESLA, INC.
  38. Remove bolt securing LH side of fascia to fender
    NOTE: 1x bolt, 10 mm, 4 N.m
    G14843666Courtesy of TESLA, INC.
  39. Remove clips securing LH front wheel liner to vehicle
    NOTE: 14x clips
    G14843667Courtesy of TESLA, INC.
  40. Remove LH front wheel liner from vehicle
    G14843668Courtesy of TESLA, INC.
  41. Remove bolt securing LH front wheel speed sensor to knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m. Discard fastener after removal
    G14843669Courtesy of TESLA, INC.
  42. Remove LH front wheel speed sensor harness from knuckle and move aside
    NOTE: 2x harness clips
    G14843670Courtesy of TESLA, INC.
    G14843671Courtesy of TESLA, INC.
  43. Remove bolt securing LH front brake caliper hose to knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m
    G14843672Courtesy of TESLA, INC.
  44. Remove LH front brake caliper from LH front knuckle
    NOTE: 2x bolts, E18, 94 N.m. Discard bolts after removal. Hang caliper off to the side with S-hook
    G14843673Courtesy of TESLA, INC.
    G14843674Courtesy of TESLA, INC.
  45. Remove bolt and nut securing LH front upper control arm to knuckle
    NOTE: 1x bolt, T47IP, 1x nyloc nut, 15 mm, 56 N.m. Recommend assistance. Compress joint to remove bolt. Discard nut after removal
    G14843675Courtesy of TESLA, INC.
    G14843676Courtesy of TESLA, INC.
  46. Remove RH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m
  47. Remove RH front fender garnish
    NOTE: 11x clips, 1x push clip, 3x tabs. Release from center of garnish and work your way outward towards both ends. Be cautious not to bend front tabs going into front fascia
    G14843677Courtesy of TESLA, INC.
    G14843678Courtesy of TESLA, INC.
    G14843679Courtesy of TESLA, INC.
    G14843680Courtesy of TESLA, INC.
  48. Remove bolt securing RH side of fascia to fender
    NOTE: 1x bolt, 10 mm, 4 N.m
    G14843681Courtesy of TESLA, INC.
  49. Remove clips securing RH front wheel liner to vehicle
    NOTE: 14x clips
    G14843682Courtesy of TESLA, INC.
  50. Remove RH front wheel liner from vehicle
    G14843683Courtesy of TESLA, INC.
  51. Remove bolt securing RH front wheel speed sensor to knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m
    G14843684Courtesy of TESLA, INC.
  52. Remove RH front wheel speed sensor harness from knuckle and move aside
    NOTE: 2x harness clips
    G14843685Courtesy of TESLA, INC.
    G14843686Courtesy of TESLA, INC.
  53. Remove bolt securing RH front brake caliper hose to knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m
    G14843687Courtesy of TESLA, INC.
  54. Remove RH front brake caliper from RH front knuckle
    NOTE: 2x bolts, E18, 94 N.m, Discard bolts after removal. Hang caliper off to the side with S-hook
    G14843688Courtesy of TESLA, INC.
    G14843689Courtesy of TESLA, INC.
  55. Remove bolt and nut securing RH front upper control arm to knuckle
    NOTE: 1x bolt, T47IP, 1x nyloc nut, 15 mm, 56 N.m. Compress joint to remove bolt, Discard after removal
    G14843690Courtesy of TESLA, INC.
    G14843691Courtesy of TESLA, INC.
  56. Disconnect 12V harness for front fascia
    NOTE: 1x locking connector, Release the locking tab by sliding it away from the connector, Then depress the grey lock to release the connector
    G14843692Courtesy of TESLA, INC.
    G14843693Courtesy of TESLA, INC.
  57. Release pedestrian warning harness
    NOTE: 1x connector, 1x clip, Pull tab to disengage lock. Pull again release from connector. Speaker is located behind RH wheel liner
    G14843694Courtesy of TESLA, INC.
  58. Release both front corners then release front of front fascia by pulling upward and away from vehicle and place onto padded surface
    NOTE: 8x clips. Recommend assistance. Use caution not to damage headlamp or fender during removal
    G14843695Courtesy of TESLA, INC.
    G14843696Courtesy of TESLA, INC.
    G14843697Courtesy of TESLA, INC.
    G14843698Courtesy of TESLA, INC.
  59. Remove bolts securing front end carrier to LH front subframe crash can assembly
    NOTE: 2x bolts, 13 mm, 16 N.m
    G14843699Courtesy of TESLA, INC.
  60. Remove bolts securing front end carrier to RH front subframe crash can assembly
    NOTE: 2x bolts, 13 mm, 16 N.m
    G14843700Courtesy of TESLA, INC.
  61. 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
  62. Remove nut securing front stabar link to LH front stabar
    NOTE: 1x nyloc nut, 18 mm, 98 N.m. Counter hold ball joint with T40. Discard after removal
    G14843701Courtesy of TESLA, INC.
  63. Move LH front stabar link assembly aside
    NOTE: May need to move the stabilizer bar up/down to get the correct angle needed to remove end link
    G14843702Courtesy of TESLA, INC.
  64. Remove nut securing front stabar to RH front stabar link assembly
    NOTE: 1x nyloc nut, 18 mm, 98 N.m. Counter hold ball joint with T40. Discard after removal
    G14843703Courtesy of TESLA, INC.
  65. Move RH front stabar link assembly aside
    NOTE: May be necessary to pull down on the sway bar to allow the end link to disengage
    G14843704Courtesy of TESLA, INC.
  66. Remove bolt and nut securing LH strut to LH front lower lateral link
    NOTE: 1x bolt, 21 mm, 1x nut, 21 mm, 106 N.m
    G14843705Courtesy of TESLA, INC.
    G14843706Courtesy of TESLA, INC.
  67. Remove bolt and nut securing RH strut to lower control arm and move the RH front lower lateral link aside
    NOTE: 1x bolt, 21 mm, 1x nut, 21 mm, 106 N.m
    G14843707Courtesy of TESLA, INC.
    G14843708Courtesy of TESLA, INC.
  68. Loosen the bolts securing front subframe to LH front subframe crash can assembly
    NOTE: 2x bolts, 15 mm, 53 N.m, This will help when installing the subframe
    G14843709Courtesy of TESLA, INC.
  69. Loosen the bolts securing front subframe to RH front subframe crash can assembly
    NOTE: 2x bolts, 15 mm, 53 N.m, This will help when installing the subframe
    G14843710Courtesy of TESLA, INC.
  70. Position coolant drain container underneath RH front of HV battery
    G14843711Courtesy of TESLA, INC.
  71. Disconnect FDU coolant inlet hose at RH front of HV battery and plug both hose ends
    NOTE: 1x spring clip
    G14843712Courtesy of TESLA, INC.
    G14843713Courtesy of TESLA, INC.
  72. Place coolant drain container below RH side of FDU
  73. Disconnect coolant hose from the FDU oil cooler to the coolant bottle and allow coolant to drain
    NOTE: 1x spring clip
    G14843714Courtesy of TESLA, INC.
  74. Install plugs to both open coolant hose connections
    NOTE: 1x spring clip
    G14843715Courtesy of TESLA, INC.
  75. Position coolant drain container below LH side of radiator
  76. Disconnect coolant hose from radiator inlet and plug both ends
    NOTE: 1x spring clip, 2x plugs
    G14843716Courtesy of TESLA, INC.
    G14843717Courtesy of TESLA, INC.
  77. Remove coolant drain container from underneath vehicle
  78. Disconnect connectors from horn assembly
    NOTE: 2x connectors
    G14843718Courtesy of TESLA, INC.
  79. Disconnect the logic connectors below steering gear
    NOTE: 2x connectors. Do not push down on red tab. Pull red tab to disengage lock. Pull again to release connector. Image zoomed out for location reference
    G14843719Courtesy of TESLA, INC.
    G14843720Courtesy of TESLA, INC.
  80. Release harness clip from subframe assembly
    NOTE: 1x clip, Image zoomed out for location reference
    G14843721Courtesy of TESLA, INC.
    G14843722Courtesy of TESLA, INC.
  81. Release harness clip from lower clip
    NOTE: 1x clip
    G14843723Courtesy of TESLA, INC.
  82. Disconnect harness from LH front rail bracket
    NOTE: 1x connector. Red locking tab. Release lock from opposite side of bracket then release connector towards front of vehicle. Image zoomed in for clarity
    G14843724Courtesy of TESLA, INC.
    G14843725Courtesy of TESLA, INC.
  83. Remove bolt securing FDU HV harness to the FDU
    NOTE: 1x bolt, EP10, 10 N.m
    G14843726Courtesy of TESLA, INC.
  84. Disconnect the FDU HV harness connector
    NOTE: 1x clip. 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 FDU header are not damaged
    G14843727Courtesy of TESLA, INC.
    G14843728Courtesy of TESLA, INC.
    G14843729Courtesy of TESLA, INC.
  85. Remove the FDU HV harness connector from the FDU and move aside
    NOTE: 1x connector
    G14843730Courtesy of TESLA, INC.
  86. Remove bolt securing FDU ground strap to FDU
    NOTE: 1x bolt, 10 mm, 6 N.m
    G14843731Courtesy of TESLA, INC.
  87. Remove FDU ground strap harness clip from FDU
    NOTE: 1x clip
    G14843732Courtesy of TESLA, INC.
  88. Loosen bolt securing FDU ground strap to HV battery and move aside
    NOTE: 1x bolt, 10 mm, 10 N.m
    G14843733Courtesy of TESLA, INC.
  89. Move the subframe lifting tool underneath the front subframe area
    G14843734Courtesy of TESLA, INC.
  90. Connect air supply to subframe lifting tool
    G14843735Courtesy of TESLA, INC.
  91. Position and support the front subframe with subframe lifting tool
    NOTE: Recommend assistance. Latch the subframe to subframe lifting tool. Make sure to align the two guides
    G14843736Courtesy of TESLA, INC.
    G14843737Courtesy of TESLA, INC.
    G14843738Courtesy of TESLA, INC.
  92. Position the rear FDU support posts to the FDU
    NOTE: Both FDU supports need to engage the FDU. The left side post is dimpled and fits into a recess on the FDU and the right side post has a teflon block that sits against the FDU. Both posts are threaded and the handle should be turned until the posts are tight
    G14843739Courtesy of TESLA, INC.
    G14843740Courtesy of TESLA, INC.
    G14843741Courtesy of TESLA, INC.
  93. Remove bolt securing the LH motor mount to the LH motor mount bracket
    NOTE: 1x bolt, E18, 105 N.m
    G14843742Courtesy of TESLA, INC.
  94. Remove bolt securing the RH motor mount to the RH motor mount bracket
    NOTE: 1x bolt, E18, 105 N.m
    G14843743Courtesy of TESLA, INC.
  95. Remove bolt securing LH mid mount to body
    NOTE: 1x bolt, 15 mm, 50 N.m. Discard after removal
    G14843744Courtesy of TESLA, INC.
  96. Remove bolt securing RH mid mount to body
    NOTE: 1x bolt, 15 mm, 50 N.m, Discard after removal
    G14843745Courtesy of TESLA, INC.
  97. Remove LH bolt securing the front portion of the front subframe to body
    NOTE: 1x bolt, 18 mm, 72 N.m. Discard after removal
    G14843746Courtesy of TESLA, INC.
  98. Remove RH bolt securing the front portion of the front subframe to body
    NOTE: 1x bolt, 18 mm, 72 N.m. Discard after removal
    G14843747Courtesy of TESLA, INC.
  99. Remove LH smaller bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 15 mm, 50 N.m. Discard after removal
    G14843748Courtesy of TESLA, INC.
  100. Remove RH smaller bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 15 mm, 50 N.m, Discard after removal
    G14843749Courtesy of TESLA, INC.
  101. Remove LH larger bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 21 mm, 125 N.m, Discard after removal
    G14843750Courtesy of TESLA, INC.
  102. Remove RH larger bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 21 mm, 125 N.m, Discard after removal
    G14843751Courtesy of TESLA, INC.
  103. Lower the subframe from vehicle
    NOTE: Recommend assistance
    G14843752Courtesy of TESLA, INC.
  104. Disconnect air supply from subframe lifting tool
    G14843753Courtesy of TESLA, INC.
  105. Remove subframe lifting tool from under vehicle
    G14843754Courtesy of TESLA, INC.
  106. Install the bushing removal cups and stud onto the RH side bushing
    NOTE: Use cups K, B, and I to drive the bushing out
    G14843755Courtesy of TESLA, INC.
    G14843756Courtesy of TESLA, INC.
    G14843757Courtesy of TESLA, INC.
  107. Press out the bushing from the FDU
    NOTE: Always apply torque to the bearing side when removing or installing a bushing, Drive the bushing until the cup and bushing assembly is free from the FDU
    G14843758Courtesy of TESLA, INC.
  108. Remove the cups and old bushing from the threaded stud
  109. Install bushing press cups with new bushing into position
    NOTE: Use cups L, J, and C, When installing a new bushing ensure the rubber tab is visible at the top of cup J
    G14843759Courtesy of TESLA, INC.
    G14843760Courtesy of TESLA, INC.
  110. Press the new bushing into the FDU
    NOTE: Always apply torque to the bearing side when removing or installing a bushing, When installing a new bushing ensure the rubber tab is visible at the top of cup J, Press the new bushing in until the flange on the bushing makes contact with the FDU case
    G14843761Courtesy of TESLA, INC.
  111. Remove the cups from the FDU and inspect the alignment of the RH bushing
    G14843762Courtesy of TESLA, INC.
    G14843763Courtesy of TESLA, INC.
  112. Position lifting tool and subframe under vehicle for installation
    G14843764Courtesy of TESLA, INC.
  113. Connect air supply to subframe lifting tool
    G14843765Courtesy of TESLA, INC.
  114. Install bolt securing the RH motor mount to the RH motor mount bracket
    NOTE: 1x bolt, E18, 105 N.m, May need adjust subfame jig to align mount with bolt hole
    G14843766Courtesy of TESLA, INC.
  115. Install bolt securing the LH motor mount to the LH motor mount bracket
    NOTE: 1x bolt, E18, 105 N.m, May need adjust subfame jig to align mount with bolt hole
    G14843767Courtesy of TESLA, INC.
  116. Raise support tool until the front subframe and body meet
    NOTE: Recommend assistance, Guide the motor mount bushings into the motor mount isolators as the lift is being raised into position, Make sure to line up the rear locating pins on the subframe
    G14843768Courtesy of TESLA, INC.
    G14843769Courtesy of TESLA, INC.
  117. Loosely install the RH larger bolt securing rear portion of the front subframe to body
    NOTE: 1x bolt, 21 mm, 125 N.m, Install new bolt
    G14843770Courtesy of TESLA, INC.
  118. Loosely install the LH larger bolt securing rear portion of the front subframe to body
    NOTE: 1x bolt, 21 mm, 125 N.m, Install new bolt
    G14843771Courtesy of TESLA, INC.
  119. Loosely install the RH smaller bolt securing rear portion of the front subframe to body
    NOTE: 1x bolt, 15 mm, 50 N.m, Install new bolt
    G14843772Courtesy of TESLA, INC.
  120. Loosely install the LH smaller bolt securing rear portion of the front subframe to body
    NOTE: 1x bolt, 15 mm, 50 N.m, Install new bolt
    G14843773Courtesy of TESLA, INC.
  121. Loosely install RH bolt securing the front portion of the front subframe to body
    NOTE: 1x bolt, 18 mm, 72 N.m, Install new bolt, Adjust subframe lifting tool if necessary
    G14843774Courtesy of TESLA, INC.
  122. Loosely install LH bolt securing the front portion of the front subframe to body
    NOTE: 1x bolt, 18 mm, 72 N.m, Install new bolt, Adjust subframe lifting tool if necessary
    G14843775Courtesy of TESLA, INC.
  123. Loosely install bolt securing the RH mid mount to body
    NOTE: 1x bolt, 15 mm, 50 N.m, Install new bolt
    G14843776Courtesy of TESLA, INC.
  124. Loosely install bolt securing the LH mid mount to body
    NOTE: 1x bolt, 15 mm, 50 N.m, Install new bolt
    G14843777Courtesy of TESLA, INC.
  125. Loosely install the bolts securing front end carrier to RH front subframe crash can assembly
    NOTE: 2x bolts, 13 mm, 16 N.m
    G14843778Courtesy of TESLA, INC.
  126. Loosely install the bolts securing front end carrier to LH front subframe crash can assembly
    NOTE: 2x bolts, 13 mm, 16 N.m
    G14843779Courtesy of TESLA, INC.
  127. Torque the RH larger bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 21 mm, 125 N.m
    G14843780Courtesy of TESLA, INC.
  128. Torque the LH larger bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 21 mm, 125 N.m
    G14843781Courtesy of TESLA, INC.
  129. Torque the RH smaller bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 15 mm, 50 N.m
    G14843782Courtesy of TESLA, INC.
  130. Torque the LH smaller bolt securing the rear portion of the front subframe to body
    NOTE: 1x bolt, 15 mm, 50 N.m
    G14843783Courtesy of TESLA, INC.
  131. Torque the RH bolt securing the front portion of the front subframe to body
    NOTE: 1x bolt, 18 mm, 72 N.m
    G14843784Courtesy of TESLA, INC.
  132. Torque the LH bolt securing the front portion of the front subframe to body
    NOTE: 1x bolt, 18 mm, 72 N.m
    G14843785Courtesy of TESLA, INC.
  133. Torque the bolt securing the RH mid mount to body
    NOTE: 1x bolt, 15 mm, 50 N.m
    G14843786Courtesy of TESLA, INC.
    G14843787Courtesy of TESLA, INC.
  134. Torque the bolt securing the LH mid mount to body
    NOTE: 1x bolt, 15 mm, 50 N.m
    G14843788Courtesy of TESLA, INC.
  135. Torque bolt and nut securing LH strut to lower control arm
    NOTE: 1x bolt, 21 mm, 1x nut, 21 mm, 106 N.m
    G14843789Courtesy of TESLA, INC.
    G14843790Courtesy of TESLA, INC.
  136. Torque bolt and nut securing RH strut to lower control arm
    NOTE: 1x bolt, 21 mm, 1x nut, 21 mm, 106 N.m
    G14843791Courtesy of TESLA, INC.
    G14843792Courtesy of TESLA, INC.
  137. Torque the bolts securing front subframe to RH front subframe crash can assembly
    NOTE: 2x bolts, 15 mm, 53 N.m
    G14843793Courtesy of TESLA, INC.
  138. Torque the bolts securing LH front subframe crash can assembly to front subframe
    NOTE: 2x bolts, 15 mm, 53 N.m
    G14843794Courtesy of TESLA, INC.
  139. Torque the bolts securing front end carrier to RH front subframe crash can assembly
    NOTE: 2x bolts, 13 mm, 16 N.m
    G14843795Courtesy of TESLA, INC.
  140. Torque the bolts securing front end carrier to LH front subframe crash can assembly
    NOTE: 2x bolts, 13 mm, 16 N.m
    G14843796Courtesy of TESLA, INC.
  141. Lower the subframe lifting tool from the vehicle
    NOTE: Unlatch the subframe lifting tool from front subframe
    G14843797Courtesy of TESLA, INC.
  142. Disconnect air supply from subframe lifting tool
    G14843798Courtesy of TESLA, INC.
  143. Remove the subframe lifting tool from vehicle
    G14843799Courtesy of TESLA, INC.
  144. Place FDU ground strap to original position and install bolt to HV battery
    NOTE: 1x bolt, 10 mm, 10 N.m
    G14843800Courtesy of TESLA, INC.
  145. Install FDU ground strap harness clip to FDU
    NOTE: 1x clip, Make sure to properly route the ground strap
    G14843801Courtesy of TESLA, INC.
    G14843802Courtesy of TESLA, INC.
  146. Install bolt securing FDU ground strap to FDU
    NOTE: 1x bolt, 10 mm, 6 N.m
    G14843803Courtesy of TESLA, INC.
  147. Connect the FDU HV harness connector and lock the release lever
    NOTE: 1x clip, Apply slight pressure to the connector as the lever is rotated into position, Move the lever to the closed position slowly and ensure the lever teeth and manifold teeth are properly meshed, There should be a very small gap between the manifold and the connector when fully seated
    G14843804Courtesy of TESLA, INC.
    G14843805Courtesy of TESLA, INC.
    G14843806Courtesy of TESLA, INC.
  148. Install bolt securing FDU HV harness to FDU
    NOTE: 1x bolt, 10 mm, 10 N.m
    G14843807Courtesy of TESLA, INC.
  149. Connect harness located at LH front rail bracket
    NOTE: 1x connector, Red locking tab, Connect from front of bracket and lock from opposite side of bracket, Image zoomed in for clarity
    G14843808Courtesy of TESLA, INC.
    G14843809Courtesy of TESLA, INC.
  150. Install upper harness clip onto lower harness clip
    NOTE: 1x clip
    G14843810Courtesy of TESLA, INC.
  151. Install lower harness clip into subframe
    NOTE: 1x clip
    G14843811Courtesy of TESLA, INC.
    G14843812Courtesy of TESLA, INC.
  152. Connect the logic connectors below steering gear
    NOTE: 2x connectors, Engage locking tabs
    G14843813Courtesy of TESLA, INC.
    G14843814Courtesy of TESLA, INC.
  153. Connect horn assembly connectors
    NOTE: 2x connectors
    G14843815Courtesy of TESLA, INC.
  154. Position coolant drain container below LH side of radiator
  155. Remove plugs and connect coolant inlet hose to LH side of radiator
    NOTE: 1x spring clip
    G14843816Courtesy of TESLA, INC.
    G14843817Courtesy of TESLA, INC.
  156. Position coolant drain container under RH side of FDU
  157. Remove plugs and connect coolant hose from coolant bottle to oil cooler
    NOTE: 1x spring clip
    G14843818Courtesy of TESLA, INC.
    G14843819Courtesy of TESLA, INC.
  158. Position coolant drain container underneath RH front of HV battery
  159. Remove plugs and connect FDU coolant inlet hose at the RH side of vehicle
    NOTE: 1x spring clip
    G14843820Courtesy of TESLA, INC.
    G14843821Courtesy of TESLA, INC.
  160. Remove coolant drain container from underneath vehicle
  161. Position the RH front stabar link assembly to front stabar
    NOTE: May be necessary to pull down on the sway bar to allow the end link to engage
    G14843822Courtesy of TESLA, INC.
  162. Install nut securing front stabar to RH front stabar link assembly
    NOTE: 1x nyloc nut, 18 mm, 98 N.m, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
    G14843823Courtesy of TESLA, INC.
  163. Position LH front stabar link assembly to front stabar
    NOTE: May be necessary to pull down on the sway bar to allow the end link to engage
    G14843824Courtesy of TESLA, INC.
  164. Install nut securing front stabar link to LH front stabar
    NOTE: 1x nyloc nut, 18 mm, 98 N.m, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
    G14843825Courtesy of TESLA, INC.
  165. Lower vehicle partially and set 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
  166. Install front fascia onto vehicle and secure front clips and both front corners
    NOTE: 8x clips, Recommend assistance, Use caution not to damage headlamp or fender during installation
    G14843826Courtesy of TESLA, INC.
    G14843827Courtesy of TESLA, INC.
    G14843828Courtesy of TESLA, INC.
  167. Connect 12V harness for front fascia
    NOTE: 1x locking connector, Engage locking tab
    G14843829Courtesy of TESLA, INC.
    G14843830Courtesy of TESLA, INC.
  168. Connect pedestrian warning harness
    NOTE: 1x connector, 1x clip, Engage locking tab
    G14843831Courtesy of TESLA, INC.
  169. Install bolt securing RH side of fascia to fender
    NOTE: 1x bolt, 10 mm, 4 N.m
    G14843832Courtesy of TESLA, INC.
  170. Install bolt and nut securing RH front upper control arm to knuckle
    NOTE: 1x bolt, T47IP, 1x nyloc nut, 15 mm, 56 N.m, Compress joint to install bolt, Install new nyloc nut
    G14843833Courtesy of TESLA, INC.
    G14843834Courtesy of TESLA, INC.
  171. Install RH front wheel speed sensor harness to knuckle
    NOTE: 2x harness clips
    G14843835Courtesy of TESLA, INC.
  172. Install bolt securing RH front wheel speed sensor to knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m
    G14843836Courtesy of TESLA, INC.
  173. Install RH front brake caliper to RH front knuckle
    NOTE: 2x bolts, E18, 94 N.m, Install new bolts, Mark with paint pen, Remove S-hook from vehicle
    G14843837Courtesy of TESLA, INC.
    G14843838Courtesy of TESLA, INC.
  174. Install bolt securing RH front brake caliper hose to RH front knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m
    G14843839Courtesy of TESLA, INC.
  175. Install RH front wheel liner to vehicle
    NOTE: 14x clips
    G14843840Courtesy of TESLA, INC.
  176. Install clips securing RH front wheel liner to vehicle
    NOTE: 14x clips
    G14843841Courtesy of TESLA, INC.
  177. Install RH front fender garnish
    NOTE: 11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
    G14843842Courtesy of TESLA, INC.
    G14843843Courtesy of TESLA, INC.
    G14843844Courtesy of TESLA, INC.
    G14843845Courtesy of TESLA, INC.
  178. Install RH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m, Start lug nuts by hand before using power tool
  179. Install bolt securing LH side of fascia to fender
    NOTE: 1x bolt, 10 mm, 4 N.m
    G14843846Courtesy of TESLA, INC.
  180. Install bolt and nut securing LH front upper control arm to knuckle
    NOTE: 1x bolt, T47IP, 1x nyloc nut, 15 mm, 56 N.m, Recommend assistance, Compress joint to install bolt, Install new nyloc nut
    G14843847Courtesy of TESLA, INC.
    G14843848Courtesy of TESLA, INC.
  181. Install LH front wheel speed sensor harness to knuckle
    NOTE: 2x harness clips
    G14843849Courtesy of TESLA, INC.
  182. Install bolt securing LH front wheel speed sensor to knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m, Install new bolt
    G14843850Courtesy of TESLA, INC.
  183. Install LH front brake caliper to LH front knuckle
    NOTE: 2x bolts, E18, 94 N.m, Install new bolts, Mark with paint pen, Remove S-hook from vehicle
    G14843851Courtesy of TESLA, INC.
    G14843852Courtesy of TESLA, INC.
  184. Install bolt securing LH front brake caliper hose to LH front knuckle
    NOTE: 1x bolt, 10 mm, 5 N.m
    G14843853Courtesy of TESLA, INC.
  185. Install LH front wheel liner to vehicle
    G14843854Courtesy of TESLA, INC.
  186. Install LH front wheel liner clips securing LH front wheel liner to vehicle
    NOTE: 14x clips
    G14843855Courtesy of TESLA, INC.
  187. Install LH front fender garnish_x000A_
    NOTE: 12x clips, 3x tabs, Start at rear and maneuver into rocker panel, Be cautious not to bend front tabs going into front fascia
    G14843856Courtesy of TESLA, INC.
    G14843857Courtesy of TESLA, INC.
    G14843858Courtesy of TESLA, INC.
    G14843859Courtesy of TESLA, INC.
  188. Install LH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m, Start lug nuts by hand before using power tool
  189. 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
  190. Install LH front wheel liner to HV battery
    NOTE: 1x clip, 1x bolt, 10 mm, 5 N.m
    G14843860Courtesy of TESLA, INC.
  191. Install RH front wheel liner to HV battery
    NOTE: 1x clip, 1x bolt, 10 mm, 5 N.m
    G14843861Courtesy of TESLA, INC.
  192. Position the front aero shield to vehicle and install nuts
    NOTE: 2x nuts, 15 mm, 5 N.m
    G14843862Courtesy of TESLA, INC.
  193. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    NOTE: 7x bolts, 10 mm, 5 N.m
    G14843863Courtesy of TESLA, INC.
  194. Lower vehicle until tires are just above the ground
    NOTE: The front wheels should still move freely for aligning the intermediate shaft, Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  195. Install fasteners holding upper portion of front fascia to vehicle
    NOTE: 5x bolts, 10 mm, 4 N.m
    G14843864Courtesy of TESLA, INC.
  196. Connect the steering gear assembly connectors
    NOTE: 2x locking connectors, Engage locking tab
    G14843865Courtesy of TESLA, INC.
  197. Slide the intermediate shaft assembly downward to install it to the steering gear assembly
    NOTE: Ensure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
    G14843866Courtesy of TESLA, INC.
  198. Install bolt securing the intermediate shaft assembly to the steering gear assembly
    NOTE: 1x bolt, 13 mm, 18 N.m
    G14843867Courtesy of TESLA, INC.
  199. 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
  200. Torque RH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m
  201. Torque LH front wheel
    NOTE: 5x nuts, 21 mm, 175 N.m
  202. Remove coolant bottle cap
    G14843868Courtesy of TESLA, INC.
  203. Place empty coolant container into front storage area
    G14843869Courtesy of TESLA, INC.
  204. Fill container with at least 15L of coolant
    G14843870Courtesy of TESLA, INC.
  205. Place filled coolant container into front storage area
    G14843871Courtesy of TESLA, INC.
  206. Setup vacuum refill tool
    NOTE: Verify all valves on refill tool are in the closed position, see image for clarity
    G14843872Courtesy of TESLA, INC.
    G14843873Courtesy of TESLA, INC.
  207. Install vacuum refill cap onto coolant bottle assembly
    G14843874Courtesy of TESLA, INC.
  208. Setup vacuum refill tool
    NOTE: Verify all valves on refill tool are in the closed position, see image for clarity
    G14843875Courtesy of TESLA, INC.
    G14843876Courtesy of TESLA, INC.
  209. Install vacuum refill hose into refill cap on coolant bottle
    NOTE: Perform push-pull-push test to verify hose is fully installed
    G14843877Courtesy of TESLA, INC.
  210. Position overflow hose into empty container
    G14843878Courtesy of TESLA, INC.
  211. Place refill hose inside filled coolant container
    NOTE: Make sure hose end is fully submerged into coolant
    G14843879Courtesy of TESLA, INC.
    G14843880Courtesy of TESLA, INC.
  212. Connect shop air supply to coolant refill tool
    NOTE: If not already done, Verify refill valve is set to off
    G14843881Courtesy of TESLA, INC.
  213. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    NOTE: Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
    G14843882Courtesy of TESLA, INC.
    G14843883Courtesy of TESLA, INC.
  214. Slowly open the refill valve to allow coolant to be drawn into the system
    NOTE: Make sure hose end of refill hose is fully submerged during entire process
    G14843884Courtesy of TESLA, INC.
  215. Once the gauge reads zero, close the refill valve
    G14843885Courtesy of TESLA, INC.
    G14843886Courtesy of TESLA, INC.
  216. Once the gauge reads zero, close the refill valve
    G14843887Courtesy of TESLA, INC.
    G14843888Courtesy of TESLA, INC.
  217. Once the gauge reads zero, close the refill valve
    G14843889Courtesy of TESLA, INC.
    G14843890Courtesy of TESLA, INC.
  218. Once the gauge reads zero, close the refill valve
    G14843891Courtesy of TESLA, INC.
    G14843892Courtesy of TESLA, INC.
  219. Disconnect shop air supply from coolant refill tool
    G14843893Courtesy of TESLA, INC.
  220. Remove coolant refill hose from coolant container
    G14843894Courtesy of TESLA, INC.
  221. Remove coolant overflow hose from coolant container
    G14843895Courtesy of TESLA, INC.
  222. Remove vacuum refill hose from refill cap on coolant bottle
    G14843896Courtesy of TESLA, INC.
  223. Remove coolant refill tool from vehicle
    G14843897Courtesy of TESLA, INC.
    G14843898Courtesy of TESLA, INC.
  224. Remove both coolant containers from inside underhood area
    G14843899Courtesy of TESLA, INC.
  225. Connect first responder loop and 12V negative terminal
    NOTE: 1x nut, 10 mm, 6 N.m, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
    G14843900Courtesy of TESLA, INC.
    G14843901Courtesy of TESLA, INC.
  226. Remove the steering wheel holder
  227. Connect to vehicle using Toolbox
    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)
  228. Select 'TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE ', 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
  229. Inspect coolant level and top off as necessary
    NOTE: Ensure that the fluid level is at the Max line
    G14843902Courtesy of TESLA, INC.
  230. Install coolant bottle cap
    G14843903Courtesy of TESLA, INC.
  231. Install frunk assembly into vehicle
    NOTE: 6x clips, Replace any clips if broken or missing
    G14843904Courtesy of TESLA, INC.
  232. Install fasteners securing the frunk assembly
    NOTE: 5x bolts, 10 mm, 5 N.m, Newer vehicles may be equipped with 1x push clip securing frunk to washer bottle neck
    G14843905Courtesy of TESLA, INC.
    G14843906Courtesy of TESLA, INC.
  233. Install access panel
    NOTE: 3x clips, 1x connector
    G14843907Courtesy of TESLA, INC.
    G14843908Courtesy of TESLA, INC.
  234. Install rear apron
    NOTE: 14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
    G14843909Courtesy of TESLA, INC.
    G14843910Courtesy of TESLA, INC.
  235. Close hood
    G14843911Courtesy of TESLA, INC.
  236. Reposition 2nd row seat cushion
    NOTE: Slide cushion rearward then align with buckles and foam with seat rail, Make sure cushion is fully seated with push & pull test
    G14843912Courtesy of TESLA, INC.
  237. Move RH front seat to original position
  238. Move LH front seat to original position
  239. Raise all four windows
  240. Close all four doors
    NOTE: If 12V is powered up, Unlatch rear doors before closing
  241. Remove vehicle from lift
    NOTE: Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  242. Check tire pressures
    NOTE: 4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar
    G14843913Courtesy of TESLA, INC.
  243. Verify the alignment slip/turn plates are locked
    G14843914Courtesy of TESLA, INC.
  244. Drive vehicle onto alignment rack
    G14843915Courtesy of TESLA, INC.
  245. Pull vehicle forward and stop ~ ft before turn plates to allow for rolling compensation
    NOTE: Shift to park
    G14843916Courtesy of TESLA, INC.
    G14843917Courtesy of TESLA, INC.
  246. Shift to park
    G14843918Courtesy of TESLA, INC.
  247. Install wheel chocks
    NOTE: Place chocks on both sides of the driver's side rear tire
    G14843919Courtesy of TESLA, INC.
  248. Latch the driver seat belt to buckle
    G14843920Courtesy of TESLA, INC.
  249. Latch LH front door and place vehicle into neutral
    NOTE: Careful not to slam the door while latch is engaged
    G14843921Courtesy of TESLA, INC.
    G14843922Courtesy of TESLA, INC.
  250. Install alignment heads onto wheels
    NOTE: 4x alignment heads
    G14843923Courtesy of TESLA, INC.
  251. Enter vehicle information to alignment machine
  252. Perform rolling compensation
    NOTE: Remove the wheel chocks from the LH rear tire and push the back of the tire to roll vehicle forward. Reinstall wheel chocks once vehicle is in position
    G14843924Courtesy of TESLA, INC.
  253. Unlock alignment slip/turn plates
    G14843925Courtesy of TESLA, INC.
  254. Verify chassis height measurement tool is calibrated
    NOTE: Adjust if necessary, Measure height of tool and adjust reading to match
    G14843926Courtesy of TESLA, INC.
    G14843927Courtesy of TESLA, INC.
  255. Perform ride height measurement
    NOTE: Measure the ride height 75 mm inward of the HV battery ski hole at each corner, If using ballast bags, move the front seats as necessary to achieve ride height spec, see Service Information for ride height specifications
    G14843928Courtesy of TESLA, INC.
  256. Apply brake pedal depressor
    G14843929Courtesy of TESLA, INC.
  257. Perform caster sweep and install steering wheel holder and level tool
    NOTE: If camber and caster are out of specification, perform necessary camber and caster adjustment
    G14843930Courtesy of TESLA, INC.
    G14843931Courtesy of TESLA, INC.
  258. Verify alignment reading is within specification and print vehicle summary
    G14843932Courtesy of TESLA, INC.
  259. Remove alignment heads from wheels
    NOTE: 4x alignment heads
    G14843933Courtesy of TESLA, INC.
  260. Remove brake pedal depressor
    G14843934Courtesy of TESLA, INC.
  261. Lock alignment slip/turn plates
    G14843935Courtesy of TESLA, INC.
  262. Lower the alignment rack to ground
    G14843936Courtesy of TESLA, INC.
  263. Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
    G14843937Courtesy of TESLA, INC.
    G14843938Courtesy of TESLA, INC.
    G14843939Courtesy of TESLA, INC.
  264. Unlatch LH front seat belt
  265. Remove wheel chocks
  266. Remove vehicle from alignment rack
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