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Home >> Tesla >> 2023 >> Model S Base >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Front Drive Unit -- Model S >> Front Drive Unit Assembly >> Drive Unit - Front - Remove And Replace >> Install
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Drive Unit - Front - Remove And Replace: Install

  1. Position the new front drive unit underneath the gantry.
    G15106398Courtesy of TESLA, INC.
  2. Use the hooks (x3) to attach the drive unit sling tool to the new rear drive unit.
    NOTE: Follow the attachment locations for the Model 3 rear drive unit.
    NOTE: New drive unit comes prefilled with EDF2.
    G15106399Courtesy of TESLA, INC.
  3. Raise the front drive unit out of the front drive unit crate.
    G15106400Courtesy of TESLA, INC.
  4. Move the transmission lift fixture to under the front drive unit.
    G15106401Courtesy of TESLA, INC.
  5. With the help of an assistant, use the gantry to lower the rear drive unit sling tool and set the drive unit onto the transmission jack fixture.
    G15106402Courtesy of TESLA, INC.
  6. Fasten the strap to secure the front drive unit to the transmission jack fixture.
    G15106403Courtesy of TESLA, INC.
  7. Lower the drive unit sling tool to release tension in the cables, and then remove the sling tool from the gantry.
    G15106404Courtesy of TESLA, INC.
  8. Remove the hooks (x3), and then remove the drive unit sling tool from the front drive unit.
    G15106405Courtesy of TESLA, INC.
  9. Sparingly use a heat gun in a shaking motion to slightly heat up the clip tabs on the breather shroud to ease installation.
    CAUTION: Do not allow the heat gun to blow constantly on the shroud, as it might melt the clip tabs.
    G15106406Courtesy of TESLA, INC.
  10. Install the breather shroud to the front drive unit, and then fasten the clip that attaches the shroud to the drive unit.
    G15106407Courtesy of TESLA, INC.
  11. Install the front drive unit HV harness to the front drive unit, and then install the bolt that attaches the harness to the drive unit.

    5 N.m (3.7 ft-lbs) +20 deg 

    G15106408Courtesy of TESLA, INC.
  12. Verify that the black release lever of the front drive unit HV harness connector is in the open position, install the connector flat and square to the front drive unit inverter HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  13. Install the front drive unit inverter to front drive unit heat exchanger hose to the front drive unit, fasten the clips (x5) that attach the hose to the drive unit, connect the hose to the inverter and to the heat exchanger, and then fasten the clips (x2) that secure the fittings.
    G15106409Courtesy of TESLA, INC.
  14. Install the front drive unit inverter hose to the front drive unit, fasten the clips (x3) that attach the hose to the drive unit, connect the hose to the front drive unit inverter, and then fasten the clip that secures the fittings.
    G15106410Courtesy of TESLA, INC.
  15. Verify that the bolts (x2) that attach the LH clevis isolator to the LH motor mount are properly torqued.

    92 N.m (67.8 lbs-ft) 

    LH motor mount removed for clarity

    G00657496Courtesy of TESLA, INC.
  16. Install the front drive unit. See DRIVE UNIT - FRONT (REMOVE AND INSTALL) .
  17. Install the LH and RH front halfshafts. See HALFSHAFT - FRONT DRIVE UNIT - LH (REMOVE AND REPLACE)  and HALFSHAFT - FRONT DRIVE UNIT - RH (REMOVE AND REPLACE) .
  18. Install the front subframe. See Subframe Assembly - Front (Remove and Install) .
  19. Install the front fascia valance. See Valance - Front Fascia (Remove and Replace) .
  20. Install the HV battery. See HV Battery (AWD) (Remove and Install) .
  21. Install the front skid plate. See Skidplate - Front (Remove and Replace) .
  22. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  23. Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace) .
  24. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace) .
  25. Install the LH and RH front wheels. See Wheel (Remove and Install) .
  26. Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.
    G15106412Courtesy of TESLA, INC.
  27. Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.
    G15106413Courtesy of TESLA, INC.
  28. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.
    G15106414Courtesy of TESLA, INC.
  29. Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.

    9 N.m (6.6 ft-lbs) 

    G15106415Courtesy of TESLA, INC.
  30. Put on the HV insulating gloves and leather over gloves.
    G15106416Courtesy of TESLA, INC.
  31. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
    NOTE: The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), escalate to Service Engineering.
    NOTE: If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
    G15106417Courtesy of TESLA, INC.
  32. Repeat step  31 for the other charge port busbar connector lead and DC input HV header bolt head.
  33. Remove the HV insulating gloves and leather over gloves.
    G15106418Courtesy of TESLA, INC.
  34. Install the bolt that secures the charge port busbar connector access door.

    9 N.m (6.6 ft-lbs) 

    G15106419Courtesy of TESLA, INC.
  35. Install the DC input HV header foam block.
    G15106420Courtesy of TESLA, INC.
  36. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace) .
  37. Install the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace) .
  38. Tighten the LH and RH front axle nuts.

    245 N.m (180.7 ft-lbs) 

    G15106421Courtesy of TESLA, INC.
  39. Fasten the clip that attaches the frunk harness to the front drive unit.
    G00657495Courtesy of TESLA, INC.
  40. Connect the frunk harness to the front drive unit harness connector, and then push in the red tab to secure.
    G00657494Courtesy of TESLA, INC.
  41. Install the bolt that attaches the ground strap to the front drive unit.

    5.5 N.m (4.1 ft-lbs) 

    NOTE: The bolt is captive to the ground strap.
    G00657493Courtesy of TESLA, INC.
  42. Remove the steering wheel lock, and then remove the protector sheet from the driver seat.
    G15106360Courtesy of TESLA, INC.
  43. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill) .
  44. Connect LV power. See LV Power (Disconnect and Connect) .
  45. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect) .
  46. Perform a firmware redeploy. See Firmware Reinstall - Toolbox .
  47. Perform a cooling system air purge. See Cooling System (Partial Refill and Bleed) .
  48. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect) .
  49. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  50. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace) .
  51. Install the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace) .
  52. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift .
  53. For China, Japan and Korea only: Carefully remove the old motor label from the hood, and install a new motor label to match the new motor information.
  54. Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension .
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