Tesla Model S: Front Drive Unit (From Below) (Remove and Install) - Removal

Special tools required for this procedure:

1. Remove the center cap from the front LH wheel and loosen the axle nut.

   

2. Recover refrigerant from the vehicle (refer to procedure).
3. Remove the front subframe (refer to procedure).
4. Remove the 12V battery bracket beam (refer to procedure).
5. Release the 2 fir tree clips that secure the 12V positive harness to the front crossmember.

   

6. Move the 12V positive harness to the RH side of the vehicle to keep it out of the working area.

   

7. Release the 4 bolts that secure the coolant reservoir to the front crossmember (torque 6 Nm). Do not remove the reservoir at this time.

   

8. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.

   

9. Ensure that the cap on the reservoir is properly secured, then pull the reservoir forward into the underhood area. Note: The reservoir hose is routed behind the drive unit hose. Note the routing of the hoses and ensure that they are routed correctly during reinstallation.

   

10. Gently pull down on the 2 coolant hoses to release the clips (x4) that secure them to the front crossmember.

    

11. Release the clip that secures the coolant reservoir hose to the A/C line.

    

12. On the LH side of the 3-way fitting, clamp the coolant hose that leads to the differential housing. Remove the hose from the front drive unit and and plug the nipple.

    

13. Move the coolant reservoir to the LH side of the vehicle and secure it out of the working area.

    Caution: The reservoir is still secured to 2 coolant hoses.

    

14. On the LH side of the drive unit, clamp the coolant hose. Remove the hose and plug the nipple. Tip: Use flexible hose clamp pliers to release the locking ring.
15. Move the clamped drive unit coolant hose to the RH side of the vehicle so that it is out of the working area.

    

16. Release the clip that secures the LH A/C line to the compressor HV harness.

    

17. Release the 2 nuts that secure the A/C lines to the compressor (torque 10 Nm). Plug both holes and cap both lines.
18. Disconnect the compressor LV harness.

    

19. Release the ground strap from the A/C compressor bracket (torque 7 Nm).

    

20. Release the edge clip that secures the LV harnesses to the compressor bracket.

    

21. Release the fir tree clip that secures the LV harnesses to the top of the front drive unit.

    

22. Wrap the LV harnesses around the RH hood strut so that they are out of the working area.
23. Have an assistant support the compressor. Release the 3 bolts that secure the A/C compressor bracket to the front drive unit (torque 10 Nm).

    

24. Move the compressor and bracket to the RH side of the vehicle and secure them outside of the working area.

    

25. Raise the vehicle to access the wheelwells.
26. Remove the front axle nuts and washers (torque 205 Nm).
27. Release the 4 screws that secure the HV cables to the front drive unit (torque 7 Nm).

    Caution: During reinstallation, carefully inspect the connector seals. If any are damaged, replace them.

    Caution: Apply P-80 emulsion to the connector seals on the HV cables before securing the HV cables during reinstallation.

    Caution: Do not apply P-80 emulsion to the HV terminals.

    

28. Fully raise the vehicle.
29. Remove the lower RH section of the acoustic cover from the drive unit.
30. Drain the gearbox fluid.
31. Clamp the 2 coolant hoses that lead to coolant pump 4.

    

32. Release the locking rings that secure the coolant hoses to coolant pump 4.
33. Remove the LH axle shaft (refer to procedure).
34. Remove the jackshaft (refer to procedure).
35. Europe only: Install the adapter plate onto the transmission jack.
36. Install the drive unit cradle onto the transmission jack.

    Non-European jack shown

    

37. Position the transmission jack fixture underneath the drive unit.
38. Raise the transmission jack to support the weight of the drive unit. Ensure that the ridge on the base of the drive unit fits into the channel on the transmission jack.

    

39. Release the bolts (x4) that secure the motor to the RH mount.

    Note: Do not fully remove the bolts from the mount; loosen the bolts in the order shown so that the motor is no longer supported by the mount. The RH motor mount is not removed in this procedure.

    

40. Release the bolts (x2) that secure the LH motor mount to the body (torque 50 Nm).
41. Lower the transmission jack and secure the drive unit with the strap.

    

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