Tesla Model 3: Bushing - Gearbox - Front Drive Unit (Remove and Replace)

Bushing - Gearbox - Front Drive Unit - Remove

SPECIAL TOOLS

Engine Motor Stand, 1000 lb. (NA, APAC) (1053595-00-A)

Engine Stand, 1000 lbs (EMEA) (1053595-01-A)

Fixture, DUF Disassembly, Model 3 (1467557-00-A)

Tool, Axle Extraction, Model 3 (1133386-00-A)

Kit, Drive Unit Bushing R&R, Model 3 (1137785-00-A)

Remove

1. Remove the front subframe assembly from the vehicle. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
2. Remove the steering rack. See Steering Rack (RWD) (Remove and Replace).
3. Install an axle extraction tool between the front drive unit and the inner joint of the LH front drive unit halfshaft, and then strike the handle end of the extraction tool with a dead blow hammer to unseat the halfshaft.
4. With assistance, remove the LH front drive unit halfshaft from the front drive unit, and then install a halfshaft plug into the opening of the gearbox.
5. Repeat steps 3 to 4 on the RH front drive unit halfshaft.

6. Release the locking tab, and then push the handle downward to disconnect the front drive unit inverter logic connector.

7. Release the red locking tab, and then press down on the tab to disconnect the resolver logic connector.

8. Release the grey locking tab, and then press down on the tab to disconnect the oil pump connector.

9. Release the clip that attaches the front drive unit harness to the front drive unit motor.

10. Release the clips that attach the front drive unit harness to the front drive unit inverter.
11. Position the subframe assembly under the gantry.

 
Other assemblies hidden for clarity

12. Position the front drive unit engine stand adapter on the front drive unit, and then hand-tighten the bolts that attach the engine stand adapter to the front drive unit.

 
Other assemblies hidden for clarity

13. Attach the gantry hook to the front drive unit engine stand adapter, as shown.
14. Raise the gantry hook until it is taut.

15. Remove the bolt that attaches the front drive unit to the front subframe.
16. Lift the front drive unit up and away from the front subframe.

Note: Make sure not to move the rear front drive unit support posts.

17. Position the front drive unit engine stand adapter on the engine stand, and then hand-tighten the bolts that attach the engine stand adapter to the engine stand.
18. Remove the gantry hook from the engine stand adapter.

19. Install the bushing tool on the front drive unit gearbox bushing.

Note: Use cups "K", "A", "H", and "L" when assembling the special tool, as shown.

20. Turn the bearing-side bushing tool nut with a wrench while holding the opposite nut in place.
21. When the bushing has been pushed out of the front drive unit gearbox, separate the bushing tool, and then remove the bushing.

Bushing - Gearbox - Front Drive Unit - Install

Install

1. Set up the bushing tool to press in the new bushing. Note: Use cups "L", "H", and "D" when assembling the special tool, as shown.

2. Turn the bearing-side bushing tool nut with a wrench until the bushing is fully installed.
3. Separate the bushing tool, and then remove it from the drive unit.

4. Attach the gantry hook to the front drive unit engine stand adapter, as shown.
5. Raise the gantry hook until it is taut.

6. Remove the bolts that attach the front drive unit engine stand adapter to the engine stand, and then set the engine stand aside.
7. Position the front drive unit over the front subframe, and then lower the front drive unit onto the front subframe.

Note: Make sure not to move the rear front drive unit support posts from their previous positions.

8. Install the bolt that attaches the front drive unit to the front subframe. Torque 80 Nm
9. Lower the gantry hook until the gantry hook is slack.

10. Remove the bolts that attach the front drive unit engine stand adapter to the front drive unit, and then set the engine stand adapter aside.
11. Move the subframe lifting tool to a working area.

12. Install the clips that attach the front drive unit harness to the front drive unit inverter.

13. Install the clip that attaches the front drive unit harness to the front drive unit motor.

14. Connect the oil pump connector, and then engage the locking tab. Important: Perform a push-pull test to verify that the connector is fully attached.

15. Connect the resolver logic connector, and then engage the locking tab. Important: Perform a push-pull test to verify that the connector is fully attached.

16. Connect the front drive unit inverter logic connector, close the handle, and then engage the locking tab. Important: Perform a push-pull test to verify that the connector is fully attached.

17. Apply approximately 1 gram of Molykote M-77 Lubricant Paste only to the hub mating face on the outboard side of the LH and RH front drive unit halfshafts.

 Caution: Do not apply any lubricant to the halfshaft splines. If lubricant is mistakenly applied, wipe the splines clean with a shop towel.

18. Remove the halfshaft plugs from the gearbox, and then with assistance, install the LH and RH front drive unit halfshafts into the front drive unit. Note: Move the LH and RH front knuckle assemblies aside to provide enough clearance to safely install the LH and RH front drive unit halfshafts.
19. Install the steering rack. See Steering Rack (RWD) (Remove and Replace).
20. Install the front subframe assembly on the vehicle. See Subframe Assembly - Front (Dual Motor) (Remove and Install).

Filter - Oil - Front Drive Unit (Remove and Replace)

Procedure

Replace the front drive unit oil filter according to the gearbox fluid procedure. See Gearbox Fluid - Front Drive Unit (Drain and Refill).