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Home >> Tesla >> 2024 >> Model 3 Base >> Repair and Diagnosis (Single Page) >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Rear Drive Unit -- Model 3 >> Rear Drive Unit Assembly >> Drive Unit Assembly - 4DU - Remove And Replace >> Install

Drive Unit Assembly - 4DU - Remove And Replace: Install

  1. Attach the 3 hooks of the drive unit sling tool to the drive unit.
    G16603950Courtesy of TESLA, INC.
  2. Secure the drive unit sling to the gantry.
    G16603951Courtesy of TESLA, INC.
  3. Raise the drive unit out of the drive unit crate.
  4. Move the subframe and lifting tool underneath the drive unit.
  5. Carefully lower the rear drive unit into the rear subframe. As the rear drive unit is lowered, maneuver the half shafts into the drive unit for later installation.
    G16603952Courtesy of TESLA, INC.
    G16603953Courtesy of TESLA, INC.
    G16603954Courtesy of TESLA, INC.
    G16603955Courtesy of TESLA, INC.
  6. Hand-tighten the LH, RH and rear bolts that attach the drive unit to subframe.
    NOTE: Torque at a later step.
    NOTE: LH Shown, RH Similar
    G16603956Courtesy of TESLA, INC.
    NOTE: Rear Bolt
    G16603957Courtesy of TESLA, INC.
  7. Lower the sling to release the tension on the cables.
  8. Hand-tighten the LH, RH and rear bolts that attach the drive unit to subframe.

    80 N.m (59.0 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
  9. Release the drive unit sling tool from the rear drive unit.
  10. Move the subframe assembly away from under the gantry.
  11. With assistance, position and align the LH half shaft axle splines into the rear drive unit.
    NOTE: Take time to make sure they are seated together correctly. Do not force them together in a way they are not meant to mate. Lift up on LH knuckle as needed.
    G16603958Courtesy of TESLA, INC.
    G16603959Courtesy of TESLA, INC.
    G16603960Courtesy of TESLA, INC.
  12. Straighten out the knuckle and the half shaft assembly, and apply shifting force to fully seat the LH rear half shaft into the rear drive unit.
    NOTE: Make sure the half shaft is fully seated. Do not apply an excessive amount force. If the half shaft is not seating, check if the splines are properly aligned and if the assembly is leveled straight.
    G16603961Courtesy of TESLA, INC.
    G16603962Courtesy of TESLA, INC.
    G16603963Courtesy of TESLA, INC.
  13. Position the LH rear toe link onto the knuckle, and then install and hand-tighten the bolt and nut.

    Tip: Recommend assistance when performing this step.

    G16603964Courtesy of TESLA, INC.
  14. Install the LH rear upper fore link to the knuckle and hand-tighten the nut and bolt.
    G16603965Courtesy of TESLA, INC.
  15. Position the LH rear upper aft link onto the knuckle, and then install and hand-tighten the bolt and nut.
    G16603966Courtesy of TESLA, INC.
  16. Install the LH wheel speed sensor connector.
    G16603967Courtesy of TESLA, INC.
  17. Repeat step  11 to step  16 for the RH side.
  18. Secure the resolver connector and the clips (x2).
    G16603968Courtesy of TESLA, INC.
    G16603969Courtesy of TESLA, INC.
  19. Secure the oil pump connector.
    G16603970Courtesy of TESLA, INC.
  20. Install the PT inverter to oil cooler hose. See HOSES - TUBE (PT), RDU INVERTER TO OIL COOLER - REMOVE AND REPLACE .
  21. Install the PT outlet hose. See HOSES - HOSE (PT), RDU OUTLET - REMOVE AND REPLACE .
  22. Install the bolts (x4) that attach the stiffener bracket to the subframe assembly.

    27 N.m (19.9 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • Cordless Ratchet/Impact Driver
    • 13 mm deep socket
    • Flex head ratchet/flex head torque wrench
    G16603971Courtesy of TESLA, INC.
  23. Position the subframe and the rear drive unit assembly under the vehicle.
  24. Connect the air supply to the subframe lifting tool.
  25. Install the rear drive unit ground strap assembly. See REAR DRIVE UNIT ASSEMBLY - ASSEMBLY, CABLE, RDU GROUND STRAP - REMOVE AND REPLACE .
  26. Install the rear drive unit HV harness assembly. See HV HARNESSES - ASSEMBLY, HV HARNESS, RDU - REMOVE AND REPLACE .
    NOTE: Back to current procedure after installing the bolt that attaches the HV battery to rear drive unit harness bracket to the rear drive unit inverter.
  27. Verify there is no coolant ingress in the rear drive unit logic connector, and then secure the connector.
    G16603972Courtesy of TESLA, INC.
  28. Secure the rear drive unit logic connection clip.
    G16603973Courtesy of TESLA, INC.
  29. Position the coolant drain container underneath the LH rear of HV battery.
  30. Install the rear drive unit inverter inlet hose. See HOSES - TUBE (PT), RDU INVERTER INLET - REMOVE AND REPLACE .
  31. Position the coolant drain container underneath the RH rear of vehicle.
  32. Remove the plugs on the ends of fittings, and then install the rear drive unit outlet hose to the PT return tube.
    NOTE: Perform a push-pull-push test to make sure that the hose is fully secured. Clean excess coolant from area.
    G16603974Courtesy of TESLA, INC.
  33. Secure the push clips (x2) that attach the RH rear wheel liner to the rocker panel.
    G16603975Courtesy of TESLA, INC.
  34. Remove the coolant drain container from underneath the vehicle.
  35. Install the HV battery rear skid plate enclosure. See HIGH VOLTAGE BATTERY ASSEMBLY - SKID PLATE, REAR, ECOAT, ENCLOSURE - REMOVE AND REPLACE .
  36. Install the clips (x4) that attach the coolant hoses to the LH and RH shear plates.
    NOTE: LH Shown, RH Similar
    G16603976Courtesy of TESLA, INC.
  37. Install the stabilizer bar assembly. See REAR STABILIZER BAR AND LINKS - REAR STABILIZER BAR ASSEMBLY - REMOVE AND REPLACE .
  38. Install the RH side subframe harness clips (x2) to body.
    G16603977Courtesy of TESLA, INC.
  39. Connect the RH side subframe harness connector.
    G16603978Courtesy of TESLA, INC.
  40. Lower the vehicle to a comfortable working height and set the lift onto locks.
  41. Install the nut that secures the rear drive unit ground strap to vehicle.

    10 N.m (7.4 lbs-ft) 

    NOTE: The nut is located at the LH rear wheel well area. If equipped, re-install the washer as well.

    Tip: Use of the following tool(s) is recommended:

    • Ratchet/torque wrench
    • 10 mm 12-point deep socket
    G16603979Courtesy of TESLA, INC.
  42. Install the bolts (x2) that attach the LH rear damper to the body at the top mount.

    41 N.m (30.2 lbs-ft) 

    NOTE: Apply pressure at top of the damper to push down and clear LH rear wheel arch liner.
    NOTE: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 15 mm socket
    • 3 in extension
    G16603980Courtesy of TESLA, INC.
  43. Install the LH rear damper connector.
    G16603981Courtesy of TESLA, INC.
    G16603982Courtesy of TESLA, INC.
  44. Install new bolts (x2) that attach the LH rear caliper to the LH rear knuckle.

    83 N.m (61.2 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • External Torx E18
    • Ratchet/torque wrench
    G16603983Courtesy of TESLA, INC.
  45. Connect the LH rear EPB caliper connector.
    G16603984Courtesy of TESLA, INC.
  46. Remove the bolt that attaches the LH rear rotor to hub.

    Tip: Use of the following tool(s) is recommended:

    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
    G16603985Courtesy of TESLA, INC.
  47. Install the hub jack adapter onto the LH rear hub and hand-tighten the lug nuts (x5).
    G16603986Courtesy of TESLA, INC.
  48. Position and raise the support stand to simulate the LH rear suspension at ride height.
    G16603987Courtesy of TESLA, INC.
  49. Use the rear ride height torque gauge to verify that the LH suspension is set to ride height specification.
    G16603988Courtesy of TESLA, INC.
  50. Measure from the bottom of quarter panel to the center of axle as a secondary check to make sure the LH suspension is set to ride height. The distance should be 378 mm.
    G16603989Courtesy of TESLA, INC.
  51. Tighten the bolt and nut that attach the LH rear upper aft link to the knuckle, and then mark the bolt and nut with a paint pen.

    134 N.m (98.8 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • 21 mm combination wrench
    • 21 mm socket
    • Flex head ratchet/flex head torque wrench
    G16603990Courtesy of TESLA, INC.
  52. Tighten the bolt and nut that attach the LH rear upper fore link to the knuckle, and then mark the bolt and nut with a paint pen.

    76 N.m (56.0 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • 18 mm combination wrench
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
    G16603991Courtesy of TESLA, INC.
  53. Tighten the bolt and nut that attach the LH rear toe link to the LH rear suspension knuckle. Mark the bolt with a paint pen.

    76 N.m (56.0 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • Cordless 3/8 in Dr Impact
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
    G16603992Courtesy of TESLA, INC.
  54. Tighten the bolt and nut that attach the LH rear lower fore link to the knuckle, and then mark the bolt and nut with a paint pen.

    76 N.m (56.0 lbs-ft) 

    G16603993Courtesy of TESLA, INC.
  55. Remove the support stand from underneath the LH rear suspension.
  56. Remove the hub jack adapter from the LH rear hub.
  57. Install the bolt that attaches the LH rear rotor to hub.

    5 N.m (3.7 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
    G16603994Courtesy of TESLA, INC.
  58. Remove the spring compressor from the LH rear coil spring.
    G16603995Courtesy of TESLA, INC.
    G16603996Courtesy of TESLA, INC.
    G16603997Courtesy of TESLA, INC.
  59. Repeat step  42 to step  58 for the RH side.
  60. Lower the vehicle to a comfortable working height and set the lift onto locks.
  61. Install the rear fascia. See BUMPER AND FASCIA - REAR BUMPER FASCIA - REAR FASCIA - REMOVE AND INSTALL .
    NOTE: Fully install the rear aero shield. See REAR UNDERTRAY AND DIFFUSER - MODEL 3/Y, REAR AERO SHIELD - REMOVE AND REPLACE .
  62. Install the LH and RH rear suspension covers. See REAR UNDERTRAY AND DIFFUSER - LH REAR SUSPENSION COVER - REMOVE AND REPLACE .
  63. Install both rear wheels. See WHEEL ASSEMBLY - REMOVE AND INSTALL .
  64. Install the 2nd row lower seat cushion. See 2ND ROW SEAT ASSEMBLIES - 2ND ROW SEAT CUSHION - REMOVE AND REPLACE .
  65. Perform a cooling system vacuum refill. See COOLING SYSTEM - VACUUM REFILL .
  66. Connect the LV battery power. See LV BATTERY - LI-ION - DISCONNECT AND CONNECT .
  67. Connect an LV maintainer. See LV MAINTAINER (CONNECT AND DISCONNECT) (MAINTENANCE) .
  68. Unlock the vehicle gateway. See GATEWAY UNLOCK .
  69. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Refrigerant System > Stop Thermal Fill Drain  , and then allow the routine to complete.
  70. Reinstall the vehicle firmware. See SOFTWARE REINSTALL - TOUCHSCREEN .
  71. Hold the brake pedal and select park on UI to disable the EPB service mode.
  72. Disconnect the LV maintainer.
  73. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Purge Start  , click Run  , and allow the routine to complete.
    NOTE:
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  74. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    NOTE: Ensure that the coolant level is at the "Max" line.
  75. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions  , then click the START  button next to Test Thermal Performance  , click Run  , and allow the routine to complete.
  76. Select the START  button next to Test HVAC Performance  , click Run  , and then allow the routine to complete.
  77. Install the cabin intake duct. See CABIN HVAC - HVAC, FRESH AIR GUTTER, ASSEMBLY - REMOVE AND REPLACE .
  78. Install the rear underhood apron. See UNDERHOOD TRIM - REAR APRON ASSEMBLY - REMOVE AND REPLACE .
  79. Close the hood and the trunk lid.
  80. Move both front seats to original position.
  81. Disable Service Mode. See SERVICE MODE .
  82. Raise all windows and close all doors.
  83. Remove the lift arms from below the vehicle.
  84. Review wheel alignment requirements and add correction code as needed.
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