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Home >> Tesla >> 2023 >> Model S Plaid >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Front Drive Unit -- Model S >> Front Drive Unit Assembly >> Drive Unit - Front - Remove And Install >> Install
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Drive Unit - Front - Remove And Install: Install

  1. Move the transmission jack fixture under the vehicle.
  2. With the help of an assistant, raise the transmission jack fixture, and maneuver harnesses and hoses around the front drive unit as it is raised into position.
    G15106344Courtesy of TESLA, INC.
  3. Install and hand tighten the bolts (x2) that attach the LH front drive unit mount to the LH casting.
    G15106345Courtesy of TESLA, INC.
  4. Raise the transmission jack fixture more to align the RH front drive unit mount with the RH casting.
    G15106346Courtesy of TESLA, INC.
  5. Install and hand tighten the bolts (x2) that attach the RH front drive unit mount to the RH casting.
    G15106347Courtesy of TESLA, INC.
  6. Tighten the bolt that attaches the rear of the RH front drive unit mount to the RH casting.

    120 N.m (88.5 ft-lbs) 

    G15106348Courtesy of TESLA, INC.
  7. Tighten the bolt that attaches the rear of the RH front drive unit mount to the RH casting.

    120 N.m (88.5 ft-lbs) 

    G15106349Courtesy of TESLA, INC.
  8. Tighten the bolts (x2) that attach the LH front drive unit mount to the LH casting.

    65 N.m (47.9 ft-lbs) 

    G15106350Courtesy of TESLA, INC.
  9. Release the strap and lower the transmission jack fixture from the front drive unit.
    G15106351Courtesy of TESLA, INC.
  10. Move the transmission jack fixture out from under the front drive unit.
    G15106352Courtesy of TESLA, INC.
  11. Install the LH cross brace to the LH casting, and then install the bolts (x3) that attach the cross brace to the casting.

    30 N.m (22.1 ft-lbs) 

    G15106353Courtesy of TESLA, INC.
  12. Install the RH cross brace to the RH casting, install the bolts (x3) that attach the cross brack to the casting, and then fasten the clips (x2) that attach the electrical harness and HVAC drain tube to the cross brace.

    30 N.m (22.1 ft-lbs) 

    G15106354Courtesy of TESLA, INC.
  13. Fasten the clips (x3) that attach the electrical harness and HVAC drain tube to the RH front frame rail.
    G15106355Courtesy of TESLA, INC.
  14. Move the coolant drain container to under the front drive unit.
    G15106356Courtesy of TESLA, INC.
  15. Remove the plugs from the fittings, immediately connect the powertrain coolant hose to the front drive unit inverter hose, and then fasten the clip that secures the fittings.
    G15106357Courtesy of TESLA, INC.
  16. Remove the plugs from the fittings, immediately connect the powertrain coolant return hose to the front drive unit heat exchanger, and then fasten the clip that secures the fittings.
    G15106358Courtesy of TESLA, INC.
  17. Move the coolant drain container out from underneath the vehicle.
    G15106359Courtesy of TESLA, INC.
  18. 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) .
  19. Install the front subframe. See Subframe Assembly - Front (Remove and Install) .
  20. Install the front fascia valance. See Valance - Front Fascia (Remove and Replace) .
  21. Install the HV battery. See HV Battery (AWD) (Remove and Install) .
  22. Install the front skid plate. See Skidplate - Front (Remove and Replace) .
  23. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  24. Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace) .
  25. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace) .
  26. Install the LH and RH front wheels. See Wheel (Remove and Install) .
  27. 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.
    G15106361Courtesy of TESLA, INC.
  28. 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.
    G15106362Courtesy of TESLA, INC.
  29. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.
    G15106363Courtesy of TESLA, INC.
  30. 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) 

    G15106364Courtesy of TESLA, INC.
  31. Put on the HV insulating gloves and leather over gloves.
    G15106365Courtesy of TESLA, INC.
  32. 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.
    G15106366Courtesy of TESLA, INC.
  33. Repeat step  32 for the other charge port busbar connector lead and DC input HV header bolt head.
  34. Remove the HV insulating gloves and leather over gloves.
    G15106367Courtesy of TESLA, INC.
  35. Install the bolt that secures the charge port busbar connector access door.

    9 N.m (6.6 ft-lbs) 

    G15106368Courtesy of TESLA, INC.
  36. Install the DC input HV header foam block.
    G15106369Courtesy of TESLA, INC.
  37. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace) .
  38. Install the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace) .
  39. Tighten the LH and RH front axle nuts.

    245 N.m (180.7 ft-lbs) 

    G15106370Courtesy of TESLA, INC.
  40. Fasten the clip that attaches the frunk harness to the front drive unit.
    G00657495Courtesy of TESLA, INC.
  41. Connect the frunk harness to the front drive unit harness connector, and then push in the red tab to secure.
    G00657494Courtesy of TESLA, INC.
  42. 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.
  43. Remove the steering wheel lock, and then remove the protector sheet from the driver seat.
    G15106360Courtesy of TESLA, INC.
  44. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill) .
  45. Connect LV power. See LV Power (Disconnect and Connect) .
  46. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect) .
  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. 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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