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Home >> Tesla >> 2024 >> Model 3 Base >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Front Drive Unit -- Model 3 >> Front Drive Unit Assembly >> Front Drive Unit Assembly - Assembly, Front 3DU, Global - Remove And Replace >> Install
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Front Drive Unit Assembly - Assembly, Front 3DU, Global - Remove And Replace: Install

  1. Position a new front drive unit and its crate underneath the gantry.
    G16603544Courtesy of TESLA, INC.
  2. Release the protective covers (x10) from the new front drive unit and transfer them onto the old drive unit.
  3. Connect the shackles (x3) to secure the drive unit sling onto the new front drive unit, and then connect the sling to the gantry.
    NOTE: Follow the instruction and the layout on the tool.
    The sling is color-coded.
    Make sure that the sling is fully and properly secured.
    G16603545Courtesy of TESLA, INC.
  4. Raise the sling until there is slight tension on the cables.
  5. Remove the bolts (x3) that attach the new front drive unit to the crate.

    Tip: Use of the following tool(s) is recommended:

    • 19 mm socket
    • Ratchet/torque wrench
    • Prybar Med
    G16603546Courtesy of TESLA, INC.
    G16603547Courtesy of TESLA, INC.
  6. Carefully lower the new front drive unit into the front subframe. As the front drive unit is lowered, maneuver the axles into the front drive unit for later installation. Line up the front drive unit with the support stands.
  7. Install the bolt that attaches the new front drive unit mount to the front subframe.

    80 N.m (59.0 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
    • Cordless 3/8 in Dr Impact
    G16603548Courtesy of TESLA, INC.
  8. Lower the sling to relieve the tension on the cables, and then disconnect the shackles (x3) to release the drive unit sling from the new front drive unit.
  9. Connect the shackles (x3) to the old front drive unit, lift the old front drive unit, and carefully lower it into the crate.
  10. Install and hand-tighten the bolts (x3) that attach the old front drive unit to the crate.
    NOTE: Raise and lower the front drive unit as needed to align the bolts. Use a prybar as required.

    Tip: Use of the following tool(s) is recommended:

    • 19 mm socket
    • Ratchet/torque wrench
    • Prybar Med
    G16603549Courtesy of TESLA, INC.
    G16603550Courtesy of TESLA, INC.
  11. Lower the sling to relieve the tension on the cables, and then disconnect the shackles (x3) to release the drive unit sling from the old front drive unit.
  12. Remove the drive unit sling from the gantry hook, and then move the old front drive unit away and prepare for the material review board (MRB).
  13. Move the front subframe away from under the gantry.
  14. Position and align the RH and the LH half shaft axle splines, and install them into the front drive unit, and then install the LH and the RH front half shafts into the front drive unit.
    NOTE:
    • Straighten out the knuckles and the half shafts, and apply a shifting force to seat the half shafts into the front drive unit.
    • Do not overexert the splines or the half shafts to avoid damage.
    • Verify that the half shafts are fully seated. If not, make sure that the splines are properly aligned, and the half shafts are leveled straight when being seated.
  15. Connect the oil pump connector.
    G16603551Courtesy of TESLA, INC.
  16. Connect the front drive unit resolver connector.
    G16603552Courtesy of TESLA, INC.
  17. Secure the front drive unit harness clip to the resolver housing.
    G16603553Courtesy of TESLA, INC.
  18. Secure the front drive unit harness clips (x2) onto the inverter housing.
    G16603554Courtesy of TESLA, INC.
  19. Connect the front drive unit inverter logic connector.
    G16603555Courtesy of TESLA, INC.
  20. Secure the clips (x2) that attach the front drive unit inverter inlet hose to the vehicle to install the hose.
    G16603556Courtesy of TESLA, INC.
  21. Secure the spring clip that attaches the front drive unit inverter inlet hose to the 90 degrees fluid coupling.
    NOTE: Perform a push-pull-push test to make sure that the hose is fully secured.
    G16603557Courtesy of TESLA, INC.
  22. Install the clips (x3) that secure the hose which attaches the front drive unit inverter to the oil cooler to the front drive unit, the inverter fluid coupling, and the heat exchanger.
    G16603558Courtesy of TESLA, INC.
    G16603559Courtesy of TESLA, INC.
    G16603560Courtesy of TESLA, INC.
  23. Position the lifting tool and the subframe under the vehicle for installation.
  24. Connect air supply to the subframe lifting tool.
  25. Install the front subframe assembly. See FRONT SUBFRAME - FRONT SUBFRAME ASSEMBLY - REMOVE AND REPLACE .
    NOTE: Start after connecting the air hose to the front subframe lifting tool, and pause after torquing the bolts (x2) that attach the LH and RH mid mounts to the body.
  26. Install the bolts (x4) that attach the front end carrier to the LH and RH front subframe crash can assemblies.

    16 N.m (11.8 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • Cordless Ratchet/Impact Driver
    • 13 mm socket
    • Ratchet/torque wrench
    • 2 in extension
    G16603561Courtesy of TESLA, INC.
    G16603562Courtesy of TESLA, INC.
  27. Install the bolts (x2) that attach the LH and RH motor mounts to the LH and RH motor mount brackets.

    105 N.m (77.4 lbs-ft) 

    Tip: Use of the following tool(s) is recommended:

    • External Torx E18
    • Flex head ratchet/flex head torque wrench
    • 3/8 in to 1/2 in adapter
    • Cordless Ratchet/Impact Driver
    • 1/4 in to 3/8 in adapter
    • 6 in extension
    • Ratchet/torque wrench
    G16603563Courtesy of TESLA, INC.
    G16603564Courtesy of TESLA, INC.
  28. Release the fixture straps from the front subframe.
  29. Lower the front subframe lifting tool from the vehicle.
  30. Disconnect the air hose from the front subframe lifting tool.
  31. Remove the front subframe lifting tool from under the vehicle.
  32. Continue to install the front subframe assembly. See FRONT SUBFRAME - FRONT SUBFRAME ASSEMBLY - REMOVE AND REPLACE .
    NOTE: Start from hand-tightening the nut and bolt that attach the LH strut to the LH front lower lateral link.
  33. Install the front fascia. See FRONT BUMPER FASCIA - FASCIA ASSEMBLY - FRONT - REMOVE AND REPLACE .
  34. Install the underhood storage unit. See EXTERIOR FITTINGS - LUGGAGE COMPARTMENT TRIM - FRONT LUGGAGE STORAGE COMPARTMENT - FRUNK ASSEMBLY - REMOVE AND REPLACE .
  35. Perform a cooling system vacuum refill. See COOLING SYSTEM - VACUUM REFILL .
    NOTE: Terminate after removing both coolant containers from the vehicle.
  36. Connect the 2nd row seat harness and secure the cushion.
  37. Connect the first responder loop and leave LV battery disconnected, then connect the LV battery maintenance-charger.
  38. Remove the steering wheel holder and the steering wheel level from the vehicle.
  39. Move the LH and RH front sear to original position.
  40. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Refrigerant System > Stop Thermal Fill Drain  , and allow the routine to complete.
  41. Locally connect a laptop with Toolbox 3 to the vehicle. See TOOLBOX 3 - CONNECT AND DISCONNECT .
  42. On the laptop, select Actions  tab and search for "Redeploy", select(i) , click run  , and allow the routine to complete.
    NOTE: The routine will state pass, but the update will continue to run in the background. UI will indicate the status of update.
  43. Once the firmware redeploy is complete, verify on center display that the release notes are present.
    NOTE: If the redeploy fails, an error message will display on the UI.
  44. Disconnect the LV battery maintenance-charger and connect the LV battery.
  45. On the touchscreen, select Thermal > Coolant System > Coolant Purge  , tap Run  , and allow the routine to complete.
    NOTE:
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  46. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    NOTE: Ensure that the coolant level is at the "Max" line.
  47. On the touchscreen, tap Thermal > Actions  , then click the START  button next to Test Thermal Performance  , click Run  , and allow the routine to complete.
  48. Disconnect the laptop.
  49. Install the rear underhood apron. See UNDERHOOD TRIM - REAR APRON ASSEMBLY - REMOVE AND REPLACE .
  50. Disable Service Mode. See SERVICE MODE .
  51. Raise all windows and close all doors.
  52. Remove the lift arms from below the vehicle.
  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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