Tesla Model S Owners & Service Manuals

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

Special tools required for this procedure:

Supplier Part Number Description
Bosch FMG-750 Transmission Jack 750 Kg Europe only
Tesla 1053350-00-A Transmission Jack Cradle Adapter Plate Europe only
Tesla 1063141-00-A 1/2 Ton Economy Transmission Jack North America, APAC only
Tesla 1048391-00-A Drive Unit Dual Motor Cradle - Delrin white
Tesla 1056566-00-A Locating Shim Set, Front Motor
Tesla 1056542-01-A Special 15mm Ratchet Wrench
Removal
  1. Remove the center cap from the front LH wheel and loosen the axle nut.

    Front Drive Unit (From Below) (Remove and Install) - Removal

  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.

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

  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.

    Front Drive Unit (From Below) (Remove and Install) - Removal

Caution: At this point in the procedure, there are still 2 coolant hoses and 1 harness attached to the reservoir.
  1. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.

    Front Drive Unit (From Below) (Remove and Install) - Removal

  2. 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.

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

  5. 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.

    Front Drive Unit (From Below) (Remove and Install) - Removal Front Drive Unit (From Below) (Remove and Install) - Removal

  6. 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.

    Front Drive Unit (From Below) (Remove and Install) - Removal

  7. 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.
  8. Move the clamped drive unit coolant hose to the RH side of the vehicle so that it is out of the working area.

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

  15. Wrap the LV harnesses around the RH hood strut so that they are out of the working area.
  16. 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).

    Front Drive Unit (From Below) (Remove and Install) - Removal

Caution: Do not spill any oil when removing the compressor.
  1. Move the compressor and bracket to the RH side of the vehicle and secure them outside of the working area.

    Front Drive Unit (From Below) (Remove and Install) - Removal

  2. Raise the vehicle to access the wheelwells.
  3. Remove the front axle nuts and washers (torque 205 Nm).
  4. 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.

    Front Drive Unit (From Below) (Remove and Install) - Removal

  5. Fully raise the vehicle.
  6. Remove the lower RH section of the acoustic cover from the drive unit.
  7. Drain the gearbox fluid.
  8. Clamp the 2 coolant hoses that lead to coolant pump 4.

    Front Drive Unit (From Below) (Remove and Install) - Removal

  9. Release the locking rings that secure the coolant hoses to coolant pump 4.
  10. Remove the LH axle shaft (refer to procedure).
  11. Remove the jackshaft (refer to procedure).
  12. Europe only: Install the adapter plate onto the transmission jack.
  13. Install the drive unit cradle onto the transmission jack.

    Non-European jack shown

    Non-European jack shown

  14. Position the transmission jack fixture underneath the drive unit.
  15. 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.

    Front Drive Unit (From Below) (Remove and Install) - Removal

Caution: Before continuing, ensure that the entire weight of the drive unit is supported by the transmission jack.
  1. 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.

    Front Drive Unit (From Below) (Remove and Install) - Removal

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

    Front Drive Unit (From Below) (Remove and Install) - Removal

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