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Home >> Tesla >> 2021 >> Model Y Performance >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> Front Drive Unit -- Model Y >> Front Drive Unit Assembly >> Fluid Coupling (Straight) - Front Drive Unit - Remove And Replace >> Install
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Fluid Coupling (Straight) - Front Drive Unit - Remove And Replace: Install

  1. Install new straight fluid coupling onto the front drive inverter
    G00628025Courtesy of TESLA, INC.
    G00628024Courtesy of TESLA, INC.
  2. Install the fastener securing the Straight fluid coupling to the front drive inverter
    NOTE: 1x screw, T25, 6 N.m
    G00628023Courtesy of TESLA, INC.
  3. Install coolant pressure test plug adapter to Straight Fluid Coupling
    NOTE: 1x spring clip, Make sure the locking clip is fully seated
    G00627952Courtesy of TESLA, INC.
  4. Install coolant pressure adapter to 55 deg Fluid Coupling
    NOTE: 1x spring clip, Make sure the locking clip is fully seated
    G00627953Courtesy of TESLA, INC.
  5. Attach coolant pressure tester to pressure fitting adapter.
    G00627954Courtesy of TESLA, INC.
  6. Attach coolant pressure tester to compressed air line.
    NOTE: Make sure valves are closed on pressure regulator
    G00627955Courtesy of TESLA, INC.
  7. Set pressure regulator to specified pressure value
    NOTE: Set pressure to 50 psi
    G00627956Courtesy of TESLA, INC.
  8. Slowly open valve on pressure regulator and allow pressure to reach specification
    G00627957Courtesy of TESLA, INC.
  9. Close the valve and let the pressure test settle.
    NOTE: Wait 16 seconds for pressure to settle, Record the reading
    G00627958Courtesy of TESLA, INC.
  10. Perform the coolant pressure leak test
    NOTE: Wait for another 12 seconds and record the reading, Max delta 0.10 psi, Check coolant hose to see if it is fully seated or not if pressure test fails
  11. Disconnect compressed air from coolant pressure tester
    G00627959Courtesy of TESLA, INC.
  12. Remove pressure fitting adapter from coolant pressure tester
    G00627954Courtesy of TESLA, INC.
  13. Remove coolant pressure tester from 55 deg Fluid Coupling.
    NOTE: 1x spring clip
    G00627953Courtesy of TESLA, INC.
  14. Remove coolant pressure test plug adapter from Straight Fluid Coupling.
    NOTE: 1x spring clip
    G00627952Courtesy of TESLA, INC.
  15. Connect the inverter to heat exchanger tube to the 90 deg Fluid Coupling
    NOTE: 1x spring clip, Perform push-pull-push test to make sure hose is fully seated
    G00628022Courtesy of TESLA, INC.
  16. Position lifting tool and subframe under vehicle for installation
    G00625541Courtesy of TESLA, INC.
    G00625539Courtesy of TESLA, INC.
  17. Connect air supply to subframe lifting tool
    G14839260Courtesy of TESLA, INC.
  18. Raise front subframe assembly onto vehicle
    NOTE: Raise front subframe assembly and line up into vehicle, Guide the motor mount bushings into the mount isolators, Verify the front struts are also positioned correctly over the front axles
    G00625539Courtesy of TESLA, INC.
    G00627962Courtesy of TESLA, INC.
    G00627963Courtesy of TESLA, INC.
    G00627964Courtesy of TESLA, INC.
    G00627965Courtesy of TESLA, INC.
  19. Thread in all bolts securing front subframe to body.
    NOTE: 2x bolts, 21mm, 125 N.m, 2x bolts, 15mm, 50 N.m, 2x bolts, 18mm, 72 N.m, 2x bolts, 15mm, 50 N.m, Line up and start threads for all fasteners, Install new fasteners, Torque at later step
    G00625533Courtesy of TESLA, INC.
  20. Loosely install the bolts securing front end carrier to RH front subframe crash can assembly
    NOTE: 2x bolts, 13mm, 16 N.m
    G14839024Courtesy of TESLA, INC.
  21. Loosely install the bolts securing front end carrier to LH front subframe crash can assembly
    NOTE: 2x bolts, 13mm, 16 N.m
    G14839058Courtesy of TESLA, INC.
  22. Torque larger bolts securing the rear portion of the front subframe to body
    NOTE: 2x bolts, 21mm, 125 N.m
    G14839035Courtesy of TESLA, INC.
    G14839040Courtesy of TESLA, INC.
    G00625536Courtesy of TESLA, INC.
  23. Torque smaller bolts securing the rear portion of the front subframe to body
    NOTE: 2x bolts, 15mm, 50 N.m
    G14839033Courtesy of TESLA, INC.
    G14839052Courtesy of TESLA, INC.
    G00625535Courtesy of TESLA, INC.
  24. Torque bolts securing the front portion of the front subframe to body.
    NOTE: 2x bolts, 18mm, 72 N.m
    G14839030Courtesy of TESLA, INC.
    G14839055Courtesy of TESLA, INC.
    G00627966Courtesy of TESLA, INC.
  25. Torque bolts securing front subframe mid mounts to body.
    NOTE: 2x bolts, 15mm, 50 N.m
    G14839047Courtesy of TESLA, INC.
    G14839028Courtesy of TESLA, INC.
    G00625534Courtesy of TESLA, INC.
  26. Torque the bolts securing front end carrier to RH front subframe crash can assembly.
    NOTE: 2x bolts, 13mm, 16 N.m
    G14839024Courtesy of TESLA, INC.
  27. Torque the bolts securing front end carrier to LH front subframe crash can assembly
    NOTE: 2x bolts, 13mm, 16 N.m
    G14839058Courtesy of TESLA, INC.
  28. 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
    G00625530Courtesy of TESLA, INC.
  29. Secure FDU resolver connection
    NOTE: 1x locking connector, Secure connection and fully engage locking tab
    G00625529Courtesy of TESLA, INC.
  30. 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
    G00625532Courtesy of TESLA, INC.
  31. Release fixture straps from front subframe
    G00625528Courtesy of TESLA, INC.
    G14839021Courtesy of TESLA, INC.
    G00625531Courtesy of TESLA, INC.
  32. Lower the subframe lifting tool from the vehicle
    NOTE: Unlatch the subframe lifting tool from front subframe
    G00627968Courtesy of TESLA, INC.
  33. Disconnect air supply from subframe lifting tool
    G14839841Courtesy of TESLA, INC.
  34. Remove the subframe lifting tool from vehicle
    G00627968Courtesy of TESLA, INC.
  35. Place FDU ground strap to original position and torque bolt to HV battery
    NOTE: 1x bolt, 10mm, 10 N.m
    G00625524Courtesy of TESLA, INC.
    G14839068Courtesy of TESLA, INC.
  36. Install FDU ground strap harness clip to FDU
    NOTE: 1x clip, Make sure to properly route the ground strap
    G00625523Courtesy of TESLA, INC.
  37. Install bolt securing FDU ground strap to FDU
    NOTE: 1x bolt, 10mm, 6 N.m
    G00625522Courtesy of TESLA, INC.
  38. Position FDU HV harness to casting for installation
    G00625521Courtesy of TESLA, INC.
    G00625520Courtesy of TESLA, INC.
    G14839070Courtesy of TESLA, INC.
  39. Secure FDU HV harness connection to FDU
    NOTE: 1x locking connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and engage red locking tab, Do not damage connetcor or header
    G00625519Courtesy of TESLA, INC.
    G00625518Courtesy of TESLA, INC.
    G00627969Courtesy of TESLA, INC.
    G00627970Courtesy of TESLA, INC.
  40. Install bolt securing FDU HV harness to FDU
    NOTE: 1x bolt, 10mm, 10 N.m
    G14843807Courtesy of TESLA, INC.
  41. Position coolant drain container under RH side of vehicle
    NOTE: Position to catch all coolant loss
    G00627971Courtesy of TESLA, INC.
  42. Remove plugs and connect FDU coolant inlet hose at the RH side of vehicle
    NOTE: 1x spring clip
    G00627972Courtesy of TESLA, INC.
  43. Remove plugs and connect coolant hose from coolant bottle to oil cooler
    NOTE: 1x spring clip
    G00627973Courtesy of TESLA, INC.
    G00627975Courtesy of TESLA, INC.
  44. Remove coolant drain container from underneath vehicle
    G00627974Courtesy of TESLA, INC.
  45. Install clips securing RH wheel liner to rocker cover
    NOTE: 3x clips, Re-position liner as needed
    G00625516Courtesy of TESLA, INC.
  46. Install front skid plate onto HV battery and secure bolts
    NOTE: 4x bolts, EP10, 13 N.m, 2x bolts, 10mm, 5 N.m
    G00627079Courtesy of TESLA, INC.
    G14838996Courtesy of TESLA, INC.
  47. 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
  48. Loosely install bolt and nut securing RH strut to RH front lower lateral link
    NOTE: 1x bolt, 21mm, 1x nut, 21mm, 106 N.m, Torque at later step
    G00625515Courtesy of TESLA, INC.
  49. Position the RH upper control arm to the knuckle and install nut and bolt
    NOTE: 1x bolt, T50, 1x nyloc nut, 15mm, 56 N.m, Compress joint to install bolt, Install new nyloc nut
    G14843833Courtesy of TESLA, INC.
    G00625514Courtesy of TESLA, INC.
  50. Position front stabar end link onto RH front strut and secure nut
    NOTE: 1x nyloc nut, 18mm, 98 N.m, Counter hold ball joint with T40, Install new fastener, Prybar can be used to relieve tension
    G00652513Courtesy of TESLA, INC.
    G00625512Courtesy of TESLA, INC.
    G00625511Courtesy of TESLA, INC.
  51. 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
    G00628020Courtesy of TESLA, INC.
  52. Install bolt securing RH front brake caliper hose to RH front knuckle
    NOTE: 1x bolt, 10mm, 5 N.m
    G00625509Courtesy of TESLA, INC.
  53. Install RH front wheel speed sensor harness to knuckle
    NOTE: 2x harness clips
    G00625507Courtesy of TESLA, INC.
  54. Install bolt securing RH front wheel speed sensor to knuckle
    NOTE: 1x bolt, 10mm, 5 N.m
    G00625506Courtesy of TESLA, INC.
  55. Connect horn assembly connectors
    NOTE: 2x connectors
    G00625505Courtesy of TESLA, INC.
  56. Loosely install bolt and nut securing LH strut to LH front lower lateral link
    NOTE: 1x bolt, 21mm, 1x nut, 21mm, 106 N.m, Torque at later step
    G00625504Courtesy of TESLA, INC.
  57. Install bolt and nut securing LH front upper control arm to knuckle
    NOTE: 1x bolt, T50, 1x nyloc nut, 15mm, 56 N.m, Compress joint to install bolt, Install new nyloc nut
    G14843847Courtesy of TESLA, INC.
    G14843675Courtesy of TESLA, INC.
  58. Position front stabar end link onto LH front strut and secure nut
    NOTE: 1x nyloc nut, 18mm, 98 N.m, Counter hold ball joint with T40, Install new fastener, Prybar can be used to relieve tension
    G00625503Courtesy of TESLA, INC.
    G00625502Courtesy of TESLA, INC.
    G00625501Courtesy of TESLA, INC.
  59. Install bolt securing LH front brake caliper hose bracket to LH front knuckle
    NOTE: 1x bolt, 10mm, 5 N.m
    G14841087Courtesy of TESLA, INC.
  60. 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
    G14841093Courtesy of TESLA, INC.
    G00625500Courtesy of TESLA, INC.
  61. Install LH front wheel speed sensor harness to knuckle
    NOTE: 2x harness clips
    G00625498Courtesy of TESLA, INC.
  62. Install bolt securing LH front wheel speed sensor to knuckle
    NOTE: 1x bolt, 10mm, 5 N.m
    G00625497Courtesy of TESLA, INC.
  63. 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
    G00627976Courtesy of TESLA, INC.
    G14843827Courtesy of TESLA, INC.
    G14843828Courtesy of TESLA, INC.
  64. Secure connection for the front fascia
    NOTE: 1x locking connector, Secure connection and fully engage red locking tab
    G14832855Courtesy of TESLA, INC.
    G14832932Courtesy of TESLA, INC.
  65. Secure connection and clip for pedestrian warning speaker
    NOTE: 1x connector, 1x clip, Engage locking tab
    G14844118Courtesy of TESLA, INC.
  66. Install bolt securing RH side of fascia to fender
    NOTE: 1x bolt, 10mm, 4 N.m
    G14844108Courtesy of TESLA, INC.
  67. Install RH front fender garnish
    NOTE: 11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
    G14844107Courtesy of TESLA, INC.
    G14843843Courtesy of TESLA, INC.
    G14844295Courtesy of TESLA, INC.
    G14843845Courtesy of TESLA, INC.
  68. Install bolt securing LH side of fascia to fender
    NOTE: 1x bolt, 10mm, 4 N.m
    G14820126Courtesy of TESLA, INC.
  69. Install clips securing LH wheel liner to fascia
    NOTE: 4x push clips
    G14820057Courtesy of TESLA, INC.
  70. Install LH front fender garnish
    NOTE: 12x clips, 3x tabs, Start at rear and maneuver into rocker panel, Be cautious not to bend front tabs going into front fascia
    G14844107Courtesy of TESLA, INC.
    G00627981Courtesy of TESLA, INC.
    G14843858Courtesy of TESLA, INC.
    G14843859Courtesy of TESLA, INC.
  71. 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
  72. Position the front aero shield to vehicle and install nuts
    NOTE: 2x nuts, 15mm, 5 N.m
    G14844308Courtesy of TESLA, INC.
  73. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    NOTE: 7x bolts, 10mm, 5 N.m
    G14843658Courtesy of TESLA, INC.
  74. Lower vehicle partially and set lift onto locks
    NOTE: Note Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  75. Install fasteners holding upper portion of front fascia to vehicle
    NOTE: 5x bolts, 10mm, 4 N.m
    G14843639Courtesy of TESLA, INC.
  76. Connect the logic connectors below steering gear
    NOTE: 2x connectors, Engage locking tabs
    G00627983Courtesy of TESLA, INC.
    G00627984Courtesy of TESLA, INC.
  77. Connect the steering gear assembly connectors
    NOTE: 2x locking connectors, Engage locking tab
    G14844311Courtesy of TESLA, INC.
  78. Secure connection for the front subframe harness
    NOTE: 1x locking connector, Red locking tab, Connect from front of bracket and lock from opposite side of bracket
    G14844258Courtesy of TESLA, INC.
    G14844259Courtesy of TESLA, INC.
  79. Slide the intermediate shaft assembly downward to install it to the steering gear assembly
    NOTE: Ensure the intermediate shaft is aligned and fully seated, if necessary to align the shaft to steering gear
    G14844436Courtesy of TESLA, INC.
  80. Install bolt securing the intermediate shaft assembly to the steering gear assembly
    NOTE: 1x bolt, 13mm, 18 N.m
    G14840806Courtesy of TESLA, INC.
  81. Install frunk assembly into vehicle
    NOTE: 6x clips, Replace any clips if broken or missing
    G14825186Courtesy of TESLA, INC.
  82. Install fasteners securing the frunk assembly
    NOTE: 5x bolts, 10mm, 5 N.m, Newer vehicles may be equipped with 1x push clip securing frunk to washer bottle neck
    G14843636Courtesy of TESLA, INC.
    G14843906Courtesy of TESLA, INC.
  83. Install access panel
    NOTE: 3x clips, 1x connector
    G14843635Courtesy of TESLA, INC.
    G00627989Courtesy of TESLA, INC.
  84. Remove coolant bottle cap
    G00627991Courtesy of TESLA, INC.
  85. Place empty coolant container into front storage area
    G00627990Courtesy of TESLA, INC.
  86. Fill container with at least 15L of coolant
    G00627992Courtesy of TESLA, INC.
  87. Place filled coolant container into front storage area
    G00627993Courtesy of TESLA, INC.
  88. Install refill tool cap onto coolant bottle assembly
    G00627994Courtesy of TESLA, INC.
  89. Setup vacuum refill tool
    NOTE: Verify all valves on refill tool are in the closed position, See image for clarity
    G00627995Courtesy of TESLA, INC.
    G00627996Courtesy of TESLA, INC.
  90. Install vacuum refill hose into refill cap on coolant bottle
    NOTE: Perform push-pull-push test to verify hose is fully engaged
    G00627997Courtesy of TESLA, INC.
  91. Place refill hose inside filled coolant container
    NOTE: Make sure hose end is fully submerged into coolant
    G00627998Courtesy of TESLA, INC.
    G00627999Courtesy of TESLA, INC.
  92. Position overflow hose into empty container
    G00628000Courtesy of TESLA, INC.
  93. Connect shop air supply to coolant refill tool
    NOTE: If not already done, Verify refill valve is set to off
    G00628006Courtesy of TESLA, INC.
  94. 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
    G00628001Courtesy of TESLA, INC.
    G00628002Courtesy of TESLA, INC.
  95. 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
    G00628003Courtesy of TESLA, INC.
  96. Once the gauge reads zero, close the refill valve
    G00628004Courtesy of TESLA, INC.
    G00628005Courtesy of TESLA, INC.
  97. Disconnect shop air supply from coolant refill tool
    G00628006Courtesy of TESLA, INC.
  98. Remove coolant refill hose from coolant container
    G00627999Courtesy of TESLA, INC.
  99. Remove coolant overflow hose from coolant container
    G00628007Courtesy of TESLA, INC.
  100. Remove vacuum refill hose from refill cap on coolant bottle
    G00628008Courtesy of TESLA, INC.
  101. Remove refill tool cap from coolant bottle assembly
    G00628009Courtesy of TESLA, INC.
  102. Remove coolant refill tool from vehicle
    G00628010Courtesy of TESLA, INC.
    G00628011Courtesy of TESLA, INC.
  103. Remove both coolant containers from inside underhood area
    G00628012Courtesy of TESLA, INC.
  104. Connect first responder loop and 12V negative terminal
    NOTE: 1x nut, 10mm, 6 N.m, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
    G14829063Courtesy of TESLA, INC.
    G14838777Courtesy of TESLA, INC.
  105. Move RH front seat to original position
  106. 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
    G00628013Courtesy of TESLA, INC.
  107. Move LH front seat to original position
  108. Remove the steering wheel holder
    G14840741Courtesy of TESLA, INC.
  109. Re-establish vehicle connection to Toolbox 3.0
  110. Select 'Actions/Autodiag' and search for 'Thermal'
  111. Select 'Stop Thermal Fluid Fill/Drain', click 'Run', and allow routine to complete
  112. Select 'Actions/Autodiag' tab and search for 'Purge'
  113. 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
  114. Inspect coolant level and top off as necessary
    NOTE: Ensure coolant is filled using G-48 coolant
    G00628014Courtesy of TESLA, INC.
  115. Install coolant bottle cap
    G00628015Courtesy of TESLA, INC.
  116. Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  117. Raise vehicle partially and lower lift onto locks
    NOTE: Set vehicle to a 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
  118. Install RH front wheel
    NOTE: 5x nuts, 21mm, 175 N.m, Start lug nuts by hand before using power tool
  119. Install LH front wheel
    NOTE: 5x nuts, 21mm, 175 N.m, Start lug nuts by hand before using power tool
  120. 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
  121. Torque LH front wheel
    NOTE: 5x nuts, 21mm, 175 N.m
  122. Install LH front wheel cap
    NOTE: 1x cap, Align valve stem with wheel cap cavity
  123. Torque RH front wheel
    NOTE: 5x nuts, 21mm, 175 N.m
  124. Install RH front wheel cap
    NOTE: 1x cap, Align valve stem with wheel cap cavity
  125. Install rear apron
    NOTE: 14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
    G14838691Courtesy of TESLA, INC.
    G00628018Courtesy of TESLA, INC.
  126. Close hood
  127. Remove vehicle from lift
    NOTE: Lower rack arms fully and remove from under vehicle
  128. Raise all four windows
  129. Close all four doors
    NOTE: If 12V is powered up, Unlatch rear doors before closing
  130. Review wheel alignment requirements and add correction code as needed
    NOTE: Note https://service.tesla.com/docs/ModelY/ServiceManual/en-us/GUID-FBF882A5-F87B-48A7-AC03-3AF71C2B11E5.html
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