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Home >> Tesla >> 2012 >> Model S >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> Front Drive Unit -- Model S >> Front Drive Unit Assembly >> Drive Unit - Front (1st Generation) - Remove And Install >> Installation
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Drive Unit - Front (1st Generation) - Remove And Install: Installation

  1. Remove the old bolts, and then hand-tighten new LH motor mount adjustment bolts (x2).
    NOTE: This step is performed with the drive unit out of the vehicle.
    G14982221Courtesy of TESLA, INC.
  2. Raise the front drive unit up into the vehicle and hand-tighten new bolts that attach the LH (x2) and RH (x2) motor mounts to the body.
    G14982222Courtesy of TESLA, INC.
    G14982223Courtesy of TESLA, INC.
    G14982224Courtesy of TESLA, INC.
  3. Install the shim kit onto the RH motor mount.
    NOTE: If the shims cannot be positioned, loosen the drive unit mount bolts and reposition the drive unit as necessary.
    G14982225Courtesy of TESLA, INC.
    G14982226Courtesy of TESLA, INC.
  4. Torque the bolts (x2) that attach the LH motor mount to the body (torque 65 N.m).
    G14982227Courtesy of TESLA, INC.
  5. Torque the LH motor mount adjustment bolts (x2) (torque 50 N.m).
    G14982228Courtesy of TESLA, INC.
  6. Torque the bolts (x2) that attach the RH motor mount to the body (torque 120 N.m).
    G14982229Courtesy of TESLA, INC.
  7. Check the fitment of the alignment shims.
    NOTE: If alignment shims do not slide in and out of place easily, loosen the LH motor mount adjustment bolts and repeat torque steps.
    G14982230Courtesy of TESLA, INC.
  8. Remove the shims from the vehicle.
    G14982231Courtesy of TESLA, INC.
  9. Release the cradle strap from the front drive unit.
  10. Lower the transmission jack, and move it out from under the vehicle.
  11. Remove the front drive unit cradle from the transmission jack.
    G14982232Courtesy of TESLA, INC.
  12. Europe only: Remove the adapter plate from the transmission jack.
  13. Install the jackshaft. See JACKSHAFT ASSEMBLY - FRONT (REMOVE AND REPLACE) .
  14. 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.

    Install the LH halfshaft. See HALFSHAFT - FRONT DRIVE UNIT - LH (1ST GENERATION) (REMOVE AND REPLACE) .

  15. Align the LH halfshaft so that the opening in the snap ring is down, facing towards the bottom of the front drive unit.
  16. Insert the LH halfshaft into the front drive unit.
    NOTE: Do not damage or displace the oil seal.
  17. 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.
  18. 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  15 and then test that the halfshaft is fully seated.
    G14982233Courtesy of TESLA, INC.
  19. Repeat step  15 through  18 for the RH halfshaft.
  20. Connect the coolant hoses to coolant pump 4, and then fasten the locking rings.
  21. Remove the clamps from the coolant hoses (x2) at coolant pump 4.
    G14982234Courtesy of TESLA, INC.
  22. Install the front drive unit lower RH acoustic cover.
  23. Lower the vehicle to a working height.
  24. Carefully inspect the connector seals of the HV cables. If any are damaged, replace them.
  25. Apply P-80 emulsion to the connector seals of the HV cables.
    CAUTION: Do not apply P-80 emulsion to the HV terminals.
    G14982235Courtesy of TESLA, INC.
  26. Insert the HV cables into the front drive unit, and then install the screws (x4) that attach the HV cables to the front drive unit (torque 7 N.m).
  27. Connect the electrical harness to the front drive unit motor logic connector.
  28. Install the ground strap to the front drive unit, and then install the bolt that attaches the ground strap to the front drive unit (torque 6 N.m).
  29. Release the compressor and bracket, and move them back to where the compressor installs.
    G14982236Courtesy of TESLA, INC.
  30. With the help of an assistant, install the bolts (x3) that attach the 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.
    G14982237Courtesy of TESLA, INC.
  31. Release the electrical harness from around the RH hood strut.
  32. Fasten the fir tree clip that attaches the electrical harness to the top of the front drive unit.
    G14982238Courtesy of TESLA, INC.
  33. Fasten the edge clip that attaches the electrical harnesses to the compressor bracket.
    G14982239Courtesy of TESLA, INC.
  34. Install the ground strap to the compressor bracket, and then install the bolt that attaches the ground strap to the compressor bracket (torque 7 N.m).
    G14982240Courtesy of TESLA, INC.
  35. Connect the electrical harness to the compressor LV connector.
    G14982241Courtesy of TESLA, INC.
  36. Remove the plugs from the A/C compressor, and remove the caps from the A/C lines.
  37. Insert the A/C lines into the compressor, and then install the nuts (x2) that attach the A/C lines to the compressor (torque 10 N.m).
  38. Fasten the clip that attaches the LH A/C line to the compressor HV harness.
    G14982242Courtesy of TESLA, INC.
  39. Return the front drive unit coolant hose from the RH side of the vehicle to the front drive unit.
    G14982243Courtesy of TESLA, INC.
  40. Unplug the fitting on the front drive unit, install the coolant hose, and then use flexible hose clamp pliers to fasten the locking ring.
  41. Remove the clamp from the coolant hose.
  42. Release the coolant reservoir, and return it from the LH side of the vehicle.
    G14982244Courtesy of TESLA, INC.
  43. Unplug the fitting on the front drive unit, install the coolant hose, and then use flexible hose clamp pliers to fasten the locking ring.
    G14982245Courtesy of TESLA, INC.
  44. Remove the clamp from the coolant hose.
    G14982246Courtesy of TESLA, INC.
  45. Fasten the clip that attaches the coolant reservoir hose to the A/C line.
    G14982247Courtesy of TESLA, INC.
  46. Fasten the clips (x4) that attach the hoses to the front crossmember.
    G14982248Courtesy of TESLA, INC.
  47. Return the coolant reservoir rearward from the underhood area.
    NOTE: Make sure that the reservoir hose is routed behind the front drive unit hose.
    G14982249Courtesy of TESLA, INC.
  48. Connect the electrical harness to the coolant level sensor connector.
    G14982250Courtesy of TESLA, INC.
  49. Install the coolant reservoir onto the front crossmember, and then install the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 N.m).
    G14982251Courtesy of TESLA, INC.
  50. Return the 12V positive harness from the RH side of the vehicle.
    G14982252Courtesy of TESLA, INC.
  51. Fasten the fir tree clips (x2) that attach the 12V positive harness to the front crossmember.
    G14982253Courtesy of TESLA, INC.
  52. Install the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  53. Install the front subframe. See Subframe Assembly - Front (1st Generation) (Dual Motor) (Remove and Install) .
  54. Recharge the A/C system. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  55. Refill the drive unit with gearbox fluid. See GEARBOX FLUID - FRONT DRIVE UNIT (1ST GENERATION) (DRAIN AND REFILL) .
  56. Install the front wheels. See Wheels - Axle Set (Remove and Install) .
  57. Engage the electric park brake.
  58. Fully lower the vehicle and remove it from the 2-post lift.
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