Tesla Model S: Subframe Assembly - Front (Remove and Install)

Special tools required for this procedure:

Removal

1. Vehicles with Air Suspension: Depressurize the air suspension (refer to procedure).
2. Loosen the lug nuts for the front wheels.
3. Remove the HV battery (refer to procedure).
4. Remove the front skid plate (refer to procedure).
5. Release the bolt that secures the air compressor bracket to the front carrier (torque 5.5 Nm).

   Note: The remaining 2 bolts that secure the bracket are removed in a later step.

   

6. If equipped: On each side of the vehicle, release the bolts (x2) that secure the staybar (torque 11 Nm).

   

7. Rear wheel drive vehicles only: Remove the nuts (x4) that secure the A/C compressor bracket to the subframe (torque 8 Nm).

   

8. Remove the bolts (x2) that secure the chiller to the subframe (torque 12 Nm).

   

9. Remove the nuts (x2), washers (x2), and rubber grommet that secure the ABS pump (torque 9 Nm).

   

10. Release the front bolt that secures the radiator bypass 3-way coolant valve to the subframe (torque 5 Nm). Note: The remaining bolt that secures the 3-way valve is removed in a later step.

    

11. Disconnect the harness connector from each 3-way valve.
12. Dual motor vehicles only: Release the clips (x2) that secure the coolant hose to the subframe.

    

13. Release the A/C drain hose from the subframe.
14. Remove the front wheels (refer to procedure).
15. Fully lower the vehicle.
16. Slide coolant pumps 1 and 2 off of the subframe brackets.
17. Release the remaining bolts (x2) that secure the chiller bypass 3-way valve to the subframe (torque 5 Nm).

    

18. Disconnect the 2 harnesses from the steering rack.

    

19. Release the bolts (x2) that secure the air compressor bracket to the subframe (torque 6 Nm).
20. Release the remaining bolt that secures the radiator bypass 3-way valve (torque 5 Nm).
21. On each side of the vehicle, release the bolt that secures the steering brace to the subframe (torque 26 Nm):
    • RWD vehicles:

    • Dual motor vehicles:

    Place a metal rod or similar across the top of the front frame rails.

22. Use tie-down cords to support the following components:
    • Air compressor, if equipped
    • ABS pump
    • Coolant pump 1
    • Coolant pump 2
    • Radiator bypass 3-way valve
    • Chiller bypass 3-way valve
23. Raise the vehicle to access the wheelwells.
24. On both sides of the vehicle, pull the rear arch liners forward.
25. On both sides of the vehicle, restrain the tie rod ball joint pin, then remove the nut that secures the tie rod end to the knuckle (torque 103 Nm).

    Caution: To prevent ball joint damage, always hold the ball joint pin with a wrench while loosening or tightening the lock nut.

    

26. Fully raise the vehicle.
27. Remove the bolt and nut that secure the front shock absorber to the rear lower control arm (torque 140 Nm).

    

28. Release the shock absorber from the lower arm.

    

29. On each side of the vehicle, remove and discard the nut that secures the sway bar to the sway bar end links (torque 70 Nm).

    Caution: Replace all nylon-insert locknuts.

    

30. On each side of the vehicle, mark a witness line on the subframe cam to aid installation, then remove the bolts that secure the front and rear lower control arms to the subframe (torque 130 Nm).
31. Remove the bolt that secures the lower intermediate shaft to the steering rack (torque 49 Nm).

    

32. Remove the bolts (x4) that secure the front subframe to the bumper carrier:
    • Composite carrier: 7.5 Nm
    • Magnesium carrier: 11 Nm

    

33. On each side of the vehicle, release the bolt that secures the steering brace to the subframe (torque 26 Nm):
    • RWD vehicles:
    • Dual motor vehicles:
34. Raise the vehicle.
35. Install the front subframe jig onto the subframe fixture.
36. Install the locating pins in the appropriate location.

    

    1	Rear wheel drive
    2	Dual motor

37. Have an assistant lower the vehicle. Guide the front subframe onto the fixture.

    

38. On each side of the vehicle, remove the 2 bolts that secure the subframe to the chassis:
    • RWD:
      1. Forward bolt (torque 140 Nm)
      2. Rear bolt (Torque 76 Nm)
    • Dual Motor:
      1. Forward bolt (torque 115 Nm)
      2. Rear bolt (Torque 115 Nm)
39. Raise the vehicle.

Installation procedure is the reverse of removal, except for the following: Warning: Only use cleaning agents and solvents in a well-ventilated area. Caution: Replace all nylon-insert locknuts. Note: Clean the affected areas before installation.

• Ensure that all subframe fixing bolts are started before attempting to tighten.
• Align the witness marks on the chassis and subframe.
• Align the suspension components to the subframe and set the cams to the previously marked positions. Do not fully tighten at this time.
• Remove the suspension from "Jack" mode and set to "Standard" and allow the suspension to settle.
• Transfer the vehicle to a 4 post lift (refer to procedure).
• Perform a 4-wheel alignment (refer to procedure) and fully torque all suspension components at ride height.

READ NEXT: