Front Drive Unit (From Below) (Remove and Install)

FRT No: 39012101

Special tools required for this procedure:

Supplier Part Number Description
Bosch FMG-750 Transmission Jack 750 Kg Europe only
Tesla 1053350-00-A Transmission Jack Cradle Adapter Plate Europe only
Tesla 1063141-00-A 1/2 Ton Economy Transmission Jack North America, APAC only
Tesla 1048391-00-A Drive Unit Dual Motor Cradle - Delrin white
Tesla 1056566-00-A Locating Shim Set, Front Motor
Tesla 1056542-01-A Special 15mm Ratchet Wrench

Removal

  1. Remove the center cap from the front LH wheel and loosen the axle nut.
  2. Recover refrigerant from the vehicle (refer to procedure).
  3. Remove the front subframe (refer to procedure).
  4. Remove the 12V battery bracket beam (refer to procedure).
  5. Release the 2 fir tree clips that secure the 12V positive harness to the front crossmember.
  6. Move the 12V positive harness to the RH side of the vehicle to keep it out of the working area.
  7. Release the 4 bolts that secure the coolant reservoir to the front crossmember (torque 6 Nm). Do not remove the reservoir at this time.

Caution: At this point in the procedure, there are still 2 coolant hoses and 1 harness attached to the reservoir.

  1. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.
  2. Ensure that the cap on the reservoir is properly secured, then pull the reservoir forward into the underhood area.
    Note: The reservoir hose is routed behind the drive unit hose. Note the routing of the hoses and ensure that they are routed correctly during reinstallation.
  3. Gently pull down on the 2 coolant hoses to release the clips (x4) that secure them to the front crossmember.
  4. Release the clip that secures the coolant reservoir hose to the A/C line.
  5. On the LH side of the 3-way fitting, clamp the coolant hose that leads to the differential housing. Remove the hose from the front drive unit and and plug the nipple.
  6. Move the coolant reservoir to the LH side of the vehicle and secure it out of the working area.
    Caution: The reservoir is still secured to 2 coolant hoses.
  7. On the LH side of the drive unit, clamp the coolant hose. Remove the hose and plug the nipple.
    Tip: Use flexible hose clamp pliers to release the locking ring.
  8. Move the clamped drive unit coolant hose to the RH side of the vehicle so that it is out of the working area.
  9. Release the clip that secures the LH A/C line to the compressor HV harness.
  10. Release the 2 nuts that secure the A/C lines to the compressor (torque 10 Nm). Plug both holes and cap both lines.
  11. Disconnect the compressor LV harness.
  12. Release the ground strap from the A/C compressor bracket (torque 7 Nm).
  13. Release the edge clip that secures the LV harnesses to the compressor bracket.
  14. Release the fir tree clip that secures the LV harnesses to the top of the front drive unit.
  15. Wrap the LV harnesses around the RH hood strut so that they are out of the working area.
  16. Have an assistant support the compressor. Release the 3 bolts that secure the A/C compressor bracket to the front drive unit (torque 10 Nm).

Caution: Do not spill any oil when removing the compressor.

  1. Move the compressor and bracket to the RH side of the vehicle and secure them outside of the working area.
  2. Raise the vehicle to access the wheelwells.
  3. Remove the front axle nuts and washers (torque 205 Nm).
  4. Release the 4 screws that secure the HV cables to the front drive unit (torque 7 Nm).
    Caution: During reinstallation, carefully inspect the connector seals. If any are damaged, replace them.
    Caution: Apply P-80 emulsion to the connector seals on the HV cables before securing the HV cables during reinstallation.
    Caution: Do not apply P-80 emulsion to the HV terminals.
  5. Fully raise the vehicle.
  6. Remove the lower RH section of the acoustic cover from the drive unit.
  7. Drain the gearbox fluid.
  8. Clamp the 2 coolant hoses that lead to coolant pump 4.
  9. Release the locking rings that secure the coolant hoses to coolant pump 4.
  10. Remove the LH axle shaft (refer to procedure).
  11. Remove the jackshaft (refer to procedure).
  12. Europe only: Install the adapter plate onto the transmission jack.
  13. Install the drive unit cradle onto the transmission jack.

    Non-European jack shown

  14. Position the transmission jack fixture underneath the drive unit.
  15. Raise the transmission jack to support the weight of the drive unit. Ensure that the ridge on the base of the drive unit fits into the channel on the transmission jack.

Caution: Before continuing, ensure that the entire weight of the drive unit is supported by the transmission jack.

  1. Release the bolts (x4) that secure the motor to the RH mount.
    Note: Do not fully remove the bolts from the mount; loosen the bolts in the order shown so that the motor is no longer supported by the mount. The RH motor mount is not removed in this procedure.
  2. Release the bolts (x2) that secure the LH motor mount to the body (torque 50 Nm).
  3. Lower the transmission jack and secure the drive unit with the strap.

Installation

Installation procedure is the reverse of removal, except for the following:
  • Use alcohol wipes to clean the mating surfaces between the RH motor mount and drive unit.
  • When securing the motor to the mounts, use the shim tools to ensure that there is sufficient clearance:
    1. Attach the 15 mm ratchet tool to a torque wrench.
      Caution: Ensure that the ratchet tool is 90 degrees perpendicular to the handle of the torque wrench when using the tool.
      1 90 degree angle
    2. Position the 3 shim tools between the RH motor mount and body.

    3. Install the bolts (x4) that secure the motor to the RH mount in the order shown (torque 75 Nm).
      Note: Use the ratchet tool to fully tighten the first and fourth bolt.
    4. Install the bolts (x3) that secure the motor to the LH mount (torque 38 Nm).
  • When installing the driveshaft into the drive unit:
    • Ensure that the opening of the snap ring is facing towards the bottom of the drive unit.
    • Do not damage or displace the oil seal.
    • Verify that the driveshaft is fully seated by carefully pushing it into the drive unit until there is an audible "click" from the snap ring.
  • Recharge the AC system.
  • Fill the drive unit with the correct amount of proper fluid:
    Note: