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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 (2nd Generation) - Remove And Install >> Remove
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Drive Unit - Front (2nd Generation) - Remove And Install: Remove

  1. Raise and support the vehicle on a 2-post lift. See Raise Vehicle - 2 Post Lift .
  2. Recover the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
    NOTE: Continue this procedure until the A/C refrigerant recovery is complete.
  3. Point the steering wheel towards the center, and then install the steering wheel holder on the steering wheel and secure the steering wheel from turning.
    G14982259Courtesy of TESLA, INC.
  4. Move the front passenger seat fully forward.
    NOTE: Note the position of the seat prior to move so that it will be returned back to its original position after this procedure is completed.
  5. Remove the rear center underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  6. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  7. Remove the front underhood apron. See Underhood Apron - Front (Remove and Replace) .
  8. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  9. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  10. Remove the underhood storage carpet. See Carpet - Underhood Storage (Remove and Install) .
  11. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  12. Disconnect 12V power. See Disconnect 12V Power .
  13. Remove the A/C recovery lines from the vehicle.
  14. Release the bolts (x3) that attach the chiller assembly to the front subframe assembly.
    G14982260Courtesy of TESLA, INC.
    G14982261Courtesy of TESLA, INC.
  15. Release the battery pump 2 off the mounting bracket by sliding the pump to the right of the vehicle.
    G14982262Courtesy of TESLA, INC.
  16. Disconnect the steering rack electrical connectors (x2).
    NOTE: Disengage the red locking tab before disconnecting the steering rack electrical connectors.
    G14982263Courtesy of TESLA, INC.
  17. Disconnect the electrical connectors (x2) for the logic for the steering rack.
    G14982264Courtesy of TESLA, INC.
  18. Release the fir tree clip that attaches the logic harness connector to the front subframe assembly.
    G14982265Courtesy of TESLA, INC.
  19. Remove the bolts (x2) that attach the air suspension pump bracket to the front subframe assembly.
    G14982266Courtesy of TESLA, INC.
  20. Secure the air suspension pump bracket and the chiller assembly to the front end carrier using bungee cords or similar.
    G14982267Courtesy of TESLA, INC.
  21. Loosen, but do not remove, the RH bolt that attaches the 3-way valve.
    G14982268Courtesy of TESLA, INC.
  22. Remove the 12V auxiliary battery. See Battery - Auxiliary - 12V (Remove and Replace) .
  23. Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  24. Disconnect the coolant reservoir level sensor electrical connector.
    G14982269Courtesy of TESLA, INC.
  25. Disconnect the A/C compressor logic electrical connector.
    G14982270Courtesy of TESLA, INC.
  26. Remove the bolt that attaches the ground connector at the A/C compressor mounting bracket.
    G14982271Courtesy of TESLA, INC.
  27. Remove the nuts (x2) that attach the A/C lines to the compressor.
    CAUTION: Remove and discard the O-rings at the A/C lines, and then put new O-rings during reinstallation.
    G14982272Courtesy of TESLA, INC.
  28. Remove the bolt that attaches the ground strap to the front drive unit assembly.
    G14982273Courtesy of TESLA, INC.
    G14982274Courtesy of TESLA, INC.
  29. Release the locking tab, and then disconnect the logic connector at the front drive unit assembly.
    G14982275Courtesy of TESLA, INC.
    G14982276Courtesy of TESLA, INC.
  30. Remove the LH and RH front lug nut covers from the front wheels using the wheel nut cover removal tool.
    G14982277Courtesy of TESLA, INC.
  31. Remove the LH and RH front wheel center caps from the vehicles using a suction cup clamp.
    G14982278Courtesy of TESLA, INC.
  32. Loosen the LH and RH front axle nuts, but do not remove them yet (torque 245 N.m).
    G14982279Courtesy of TESLA, INC.
  33. Loosen, but do not remove at this time, the LH and RH front lug nuts (torque 175 N.m).
    G14982280Courtesy of TESLA, INC.
  34. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift .
  35. Remove the LH and RH front wheels.
  36. Remove and discard the RH nyloc nut that attaches the tie rod end to the steering knuckle, and then disconnect the tie rod from the steering knuckle. Repeat this step on the LH tie rod end.
    NOTE: RH tie rod
    G14982281Courtesy of TESLA, INC.
    NOTE: LH tie rod
    G14982282Courtesy of TESLA, INC.
  37. Remove the RH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace) .
  38. Raise the vehicle fully. See Raise Vehicle - 2 Post Lift .
  39. Remove the mid aero shield. See Panel - Aero Shield - Mid (Remove and Replace) .
  40. Remove the front extrusion bash plate. See Bash Plate - Front - Extrusion (Remove and Replace) .
  41. Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install) .
  42. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace) .
  43. Remove the front subframe skid bar. See Skid Bar - Front Subframe (Remove and Replace) .
  44. Remove the front bash plate stamping. See Bash Plate - Front - Stamping (Remove and Replace) .
  45. Remove the front skidplate. See Skidplate - Front (Remove and Replace) .
  46. Remove the bolt that attaches the RH front strut to the front lower aft link. Repeat this step on the LH front strut.
    NOTE: RH side
    G14982283Courtesy of TESLA, INC.
    NOTE: LH side
    G14982284Courtesy of TESLA, INC.
  47. Remove the bolt that attaches the LH front lower aft link to the front subframe assembly, and then move the link aside.
    NOTE: Index the location of the eccentric with a paint marker.
    G14982285Courtesy of TESLA, INC.
  48. Remove the bolt that attaches LH front lower fore link to the front subframe assembly, and then move the link aside.
    NOTE: Index the location of the eccentric with a paint marker.
    G14982286Courtesy of TESLA, INC.
  49. Remove the bolt that attaches the RH front lower aft link to the front subframe assembly, and then move the link aside.
    NOTE: Index the location of the eccentric with a paint marker.
    G14982287Courtesy of TESLA, INC.
  50. Remove the bolt that attaches the RH front lower fore link to the front subframe assembly, and then move the link aside.
    NOTE: Index the location of the eccentric with a paint marker.
    G14982288Courtesy of TESLA, INC.
  51. Remove and discard the nut that attaches the LH stabilizer bar to the stabilizer bar end link, and then remove the end link from the stabilizer bar. Repeat this step on the RH stabilizer bar.
    NOTE: LH shown, RH similar
    G14982289Courtesy of TESLA, INC.
  52. Remove the bolt that attaches the lower i-shaft to the steering rack, and then slide the i-shaft up and away from the steering rack.
    G14982290Courtesy of TESLA, INC.
  53. Remove the forward bolt that attaches the RH 3-way valve to the subframe bracket.
    G14982291Courtesy of TESLA, INC.
  54. Remove the bolts (x2) that attach the LH stay bar to the front subframe assembly. Repeat this step on the RH stay bar.
    G14982292Courtesy of TESLA, INC.
  55. Remove the nuts (x2) that attach the ABS pump to the front subframe, and then release the ABS pump from the rubber mounting grommet.
    G14982293Courtesy of TESLA, INC.
  56. Put the coolant drain container under the LH corner of the vehicle to catch any coolant during the next step.
  57. Disconnect the front drive unit inlet hose, and then plug both openings with hose plugs.
    G14982294Courtesy of TESLA, INC.
  58. Release the hose clamp that attaches the battery coolant heater-to-coolant pump 2 at the rear of the front subframe assembly, and then plug both ends using plugs from the coolant hose plug kit.
    G14982295Courtesy of TESLA, INC.
  59. Release the fir tree clips (x3) that attach the battery coolant heater-to-coolant pump 2 between the steering rack and the front subframe assembly.
    G14982296Courtesy of TESLA, INC.
  60. Move the coolant drain container to the RH corner of the vehicle to catch any coolant during the next step.
  61. Release the hose clip and the fir tree clip that attach the coolant hose from the radiator inlet, and then plug both ends using plugs from the coolant hose plug kit.
    G14982297Courtesy of TESLA, INC.
    G14982298Courtesy of TESLA, INC.
  62. Remove the coolant drain container from under the vehicle.
  63. Remove and discard the bolts (x4) that attach the Front Junction Box (FJB)-to-front drive unit HV harness to the FJB.
    G14982299Courtesy of TESLA, INC.
  64. Disconnect the A/C HV cable from the FJB.
    G14982300Courtesy of TESLA, INC.
  65. Position the powertrain table with the Model S/X subframe adapter installed under the front of the vehicle.
  66. Connect shop air supply to the powertrain table.
  67. Raise the powertrain table into position.
    G14982301Courtesy of TESLA, INC.
    NOTE: Make sure that the pins are installed into the correct positions on the fixture.
    NOTE: Make sure that the pins engage the front subframe assembly so that it is properly supported.
    G14982302Courtesy of TESLA, INC.
    G14982303Courtesy of TESLA, INC.
  68. Remove and discard the bolts (x4) that attach the bumper carrier to the front subframe assembly.
    NOTE: LH side
    G14982304Courtesy of TESLA, INC.
    NOTE: RH side
    G14982305Courtesy of TESLA, INC.
  69. Remove the bolt that attaches the LH stabilizer bar mount to the body through the front subframe assembly. Repeat this step on the RH stabilizer bar mount.
    NOTE: LH side
    G14982306Courtesy of TESLA, INC.
  70. Remove the LH rear bolt that attaches the front subframe assembly to the body. Repeat this step on the RH rear bolt.
    NOTE: LH side
    G14982307Courtesy of TESLA, INC.
    NOTE: RH side
    G14982308Courtesy of TESLA, INC.
  71. Lower the front subframe assembly completely, and then move the front subframe assembly from under the vehicle.
    CAUTION: Do not work on the front subframe assembly while it is under the vehicle.
    CAUTION: Do not damage the front end carrier while the front subframe assembly is lowered from the vehicle. The powertrain table must be tilted on the rear side angle down and the front side tilted up as the front subframe is clearing the front end carrier.
  72. Partially lower the vehicle partially.
  73. Remove the LH and RH front axle nuts, and remove and discard the washers.
    G14982309Courtesy of TESLA, INC.
  74. Install the hydraulic hub puller on the LH front brake rotor using 2 lug nuts and 2 hydraulic hub puller washers.
    G14982310Courtesy of TESLA, INC.
  75. Separate the LH halfshaft from the hub splines using the hydraulic hub puller, and then remove the puller from the hub.
    G14982311Courtesy of TESLA, INC.
  76. Remove the LH halfshaft from the hub assembly.
  77. Install the axle removal tool around the inner joint of the halfshaft.
    G14982312Courtesy of TESLA, INC.
    NOTE: Use a cable tie to secure the axle removal tool in place.
    NOTE: Close-up view of axle removal tool on halfshaft
    G14982313Courtesy of TESLA, INC.
  78. Remove the halfshaft from the front drive unit using the axle removal tool, and then remove the halfshaft from the vehicle.
  79. Repeat step  74 -  78 on the RH halfshaft.
  80. Position the front drive unit stand and underhoist stand under the vehicle.
    G14982314Courtesy of TESLA, INC.
  81. Remove the bolts (x2) that attach the LH front drive unit mount to the body.
    G14982315Courtesy of TESLA, INC.
  82. Remove the bolts (x2) that attach the RH front drive unit mount to the body.
    G14982316Courtesy of TESLA, INC.
    G14982317Courtesy of TESLA, INC.
  83. Use the transmission jack and the MS/X drive unit cradle to lower the front drive unit assembly out of the vehicle.
    G14982318Courtesy of TESLA, INC.
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