Tesla Motor Leak Tests and Final Assembly

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There are alignment marks on the rotor spline end face and the gearbox primary shaft. Thanks to TMC member howardc64. Both parts may have been balanced combined. I did not notice the marks nor did I align them.
In this episode, I do very basic short term leak testing and the final assembly of the Tesla Drive Unit. Learn and do better :-)
Timestamps
0:00 intro
0:10 torqueing the gearbox
0:33 add gear box fluid (Dexron VI)
1:57 wait and check for leak
3:08 mount reluctor wheel
4:41 fix differential sealant
6:01 drain gear box fluid
6:24 engage parking pawl (Toyota and Mercedes only)
7:30 hoist down LDU to ground and put upright
8:01 greate rotor spline, clean, final checks
8:32 add sealant to rotor housing
9:00 mount rotor
9:58 add sealant to rotor manifold
10:15 mount manifold
10:58 mount coolant pipe
12:11 leak test
13:25 mount sensor wires
15:26 bolt down AC conductors and cap
15:54 gear box fluid fluid level visualization
See also
sites.google.com/view/teslald...
www.myrav4ev.com
For more info about the gearbox' oil pump, See Weber University's Channel:
• Understanding the Tesl...
Disclaimer
This video is for entertainment purposes only. All work you do on your car is at your own risk.
Keywords
Toyota RAV4 2012 2013 2014 Mercedes B-class Electric Drive Tesla Model S large drive unit LDU motor BEV glycol coolant fluid Zerex G48 automatic transmission fluid ATF Dexron VI leak battery aegis ring bearing bearings grinding noise CAD model PTFE teflon rotary lip seal failure drain housing rotor shaft repair common mode grounding runout eccentricity fluting wear axial radial play speed sensor check rebuild assemble disassemble vent reluctor ring expensive cheap repair DIY out of warranty

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Опубликовано:

4 июл 2024

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Комментарии : 48

@ai_virtual_life Год назад

Thanks for video. Some add: An inductive motor (without a permanent magnets) does not produce electricity without an excitation voltage. In other words, you could spin it without the risk of damaging the inverter. But even if there was a permanent magnets motor. By default, IGBT transistors will work as a diode bridge. You would hardly be able to spin it so that the voltage on the common capacitor of the inverter would exceed the allowable one...

@diyEVguy Год назад

Thanks! I was wondering about that...

@moestrei 5 месяцев назад

There could be some magnetism left (called Remanenz in German) in the rotor which theoretically induce some current into the stator windings. as you said better safe than sorry. Really like how much thought and research you put in about every step you do. If you would be a pilot I would happily fly with you. When you think about it isn't it totally amazing that two very conservative manufacturers get a new start-up with a completely new product to supply drivetrains and battery packs for their established vehicles? How did that ever happen? And while Merc does make decent EVs now days, Toyota is kinda the opposite, still dreaming of Hydrogen and fossil fuel. Just amazing.

@peteroffpist1621 5 месяцев назад

Best instructional video ever.

@diyEVguy 5 месяцев назад

Thanks!

@rothvisuals 10 месяцев назад

I'm so glad I found your video - it helped me work through and find peace of mind after discovering the speed sensor test on my original LDU on my 2013 Model S. My speed sensor was wet... So, using LOTS of your guidance from your videos, website, the forums and photos I found, I just did some drain holes without removing the LDU. I filmed it and will share a link when I upload the video. Hopefully lots more people will be able to do this as well and prevent the inevitable damage from leaks!

@diyEVguy 10 месяцев назад

Thanks for sharing. Glad it helped.

@krisztiankulcsar5579 9 месяцев назад

That's awesome I'm thinking about doing the same. Could you share your experience with adding the drain holes to the motor. Your video would be a GIANT help. Thank you

@rothvisuals 9 месяцев назад

You've got it! Need to spend an hour or two putting it together @@krisztiankulcsar5579

@gaborecseri8013 8 месяцев назад

when will you upload the video?

@Gojek-fp1bm Год назад

Great work

@rothvisuals 10 месяцев назад

Love it!!

@eastmanresearch3143 Год назад

You've done a hell of a job rebuilding this unit. I do wonder if it's the main o-ring that's failing, if its possible to put some fluid in the coolant and/or transmission fluid which might swell it a bit to last another few years like some guys do w/ power steering pumps. I think the emergency drains are great, because you should be able to know very quickly when a problem develops and hopefully the bearings are not destroyed quickly by the contamination. It's a huge PIA to get the car on a lift and check the speed sensor area for moisture/coolant unless you own a shop. The emergency drains could be used with a small reservoir and a sensor to alarm the owner of a problem. In theory if you can link your phone to the canbus/obd2 port you could setup a proprietary OID to alarm for this condition with a canbus sensor and a small microcontroller. I would pay hundreds of dollars for that feature if it could alert me quickly. I have some hardware with canbus support and it would not take too much to make this feature accessible. I think the question is where can the canbus (125k/s) be tapped into in the rear of the car.

@diyEVguy Год назад

The coolant seal lip is made of PTFE (Teflon), which is "compatible" with almost all chemicals you can think of, so it's highly unlikely you can find an additive that works. See for example www.foxxlifesciences.com/pages/ptfe-and-teflon-chemical-compatibility-chart.

@diyEVguy Год назад

I think with the Tesla, you do not necessarily need a car lift, but it still is a pain compared to a sensor: See a sensor concept here (buzzer and LED on dash): ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-ps2gha4w5YE.html I will ask if he sells them.

@eastmanresearch3143 Год назад

@@diyEVguy Are you using the same seal as qccharge recommends w/ the 3 lip layer? I have a bad feeling my DU when replaced in 2020 has the single lip which qccharge employee states fails early. Also, are the drains in the same spot as how qccharge installs them? They want $1750 to do an upgrade to new seals and drains. I'm considering it for that price, much cheaper than the alternative.

@diyEVguy Год назад

@@eastmanresearch3143 No, QC Charge said that they use a custom made seal: teslamotorsclub.com/tmc/posts/5280769/ Also I do not know where QC Charge puts their drains. Here is one (older?) idea (which I do not fully understand based on the photo alone), posted on Sep 6, 2021: www.myrav4ev.com/forum/viewtopic.php?t=2332&hilit=rebuild&start=30

@osamamg4784 Год назад

Perfect video and accuracy in work. I am from Syria and I am trying to design this engine in the SolidWorks 3D design program, but I am facing a problem, which is that I do not have the necessary dimensions to draw and design gears, and I do not have enough insight to assemble the parts. I searched a lot on the Internet and did not find anything really useful. I drew and designed the Stator and the Rotor, but I still lack the dimensions of the structure and the rest of the parts. Can you suggest a solution to help?? I've watched all of your videos and have good ideas about the engine's internal structure, but I'm still missing the dimensions and some parts combinations.

@diyEVguy Год назад

You could buy a broken or fire-damaged drive unit from a junk yard and measure a lot but that will take you weeks. What is the goal of the 3D model? Some kind of simulation? I did not model the gears and inverter, just the electric motor segment, because that is all I needed. Also Sandy Munroe may sell 3D scans of all parts for $10000 or so. What is your budget?

@Star3 Год назад

amazing work!! what was the time frame on this?

@diyEVguy Год назад

For me incl video editing and waiting for parts etc: 8 weeks or so. Next time without recoding I could do it over two weekends if I am lucky.

@johnstuder847 Месяц назад

I think these units have sealed bearings on the motors. These bearings will fail at some point, I have not seen all your videos, but if you are doing this much work, might as well replace. Also, there is a replacement / update for the coolant bypass tube, better design that avoids the seal failure issue altogether.

@johnstuder847 Месяц назад

Just saw the other video with the bearing repacking. No way those sealed bearings will last 100k miles. Are all Tesla motors designed with sealed bearings? I’d rather change oil than pull that motor every 100k miles.

@diyEVguy Месяц назад

@@johnstuder847 early models had steel ball rotor bearings. Later they switched to hybrid ceramic bearings.

@diyEVguy Месяц назад

Yeah and many questions remain. Like will the rotor overheat? Is there enough statistical data from real world experience etc.

@donx03 Год назад

Excellent work, my P85D rear motor went, Tesla says it's internal motor failure, it's water damaged, they don't know where the water came from. They want 10k + taxes to fix, I'm no expert, but seems like a failed coolant seal could be the problem, this should be a class action lawsuit.

@diyEVguy Год назад

Yeah we try to get a handle on how long this motor lasts. For seal longevity data, we started this page: sites.google.com/view/teslaldu/longevity What is your plan with the car? Has the coolant destroyed the inverter electronics?

@spindlehospital5263 3 месяца назад

spray welding just for worn bearing journals not suitable for sealing surfaces it makes lips worn for best result laser welding or chrome plating

@spindlehospital5263 3 месяца назад

don’t use liquid for test we use air for leaks detection first close the inlet than give 2 bar air to systsem than check it with leak detection

@diyEVguy 3 месяца назад

Do you put soapy water on the outside to see where it starts foaming? Or just listen for a hissing sound? O wait first you just watch whether the pressure stays the same.

@spindlehospital5263 3 месяца назад

@@diyEVguy can you see my comment please share your email with me

@omarmalyomarmaly9323 Год назад

7:15 assembled gearbox and my axeks are rotating with knock knock sound like the watch, what i got to do? Sound looks like from invertor or gearbox, and i did not fix the parking break -what kind of damage i did i dont know right now... And i just thoug the park brake doesnt work

@diyEVguy Год назад

Pull axles out, run motor again and listen again?

@omarmalyomarmaly9323 Год назад

@@diyEVguy without axles mb b250 electro goes to safe mode sad i need to go to service withoutgearbox selection ,and what app do i need to delete mistakes from ebu... Elm327 i already have but cant find app to read the ebu , i think its goes to error becouse i forgot to setup the brake support on the disk , push brake pedal and its eroor i have

@diyEVguy Год назад

@@omarmalyomarmaly9323 I would recommend contacting alflash.com.ua because you can trust him, he helped me too. I have a full-time job now so I cannot help more.

@omarmalyomarmaly9323 Год назад

@@diyEVguy just , send the message. Iput axls in the place and engage the park brake but its stil rotating and the electric motor is clicking, mb was some wrong assemling? And i need to pull out the motor? And repack it?

@diyEVguy Год назад

@@omarmalyomarmaly9323 can you make a short video about it and post it on RU-vid?

@hishamqdoumi1786 Год назад

Is this the same motor in Mercedes b250e

@diyEVguy Год назад

Almost the same, but the inverter electronics hardware is different according to @CarRepairVideos

@hishamqdoumi1786 Год назад

@@diyEVguy im looking to remove my motor Mercedes b250e for a bearings noise,im a mechanic but i have never removed one,is there any instructions video for removal?thank you for your useful videos

@diyEVguy Год назад

@@hishamqdoumi1786 For bearings, my videos should be showing the same (or at least very similar) parts and procedures as for your motor. I am very curious what you will find! Please keep me up to date. Did you check for the infamous coolant leak yet?

@diyEVguy Год назад

@@hishamqdoumi1786 Check this too: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-1ecX94hxewc.html