2024 Tesla Model 3 RDU Oil Loss Through Breather TSB

Tesla Service Bulletin SB-24-40-008, issued on October 15, 2024, details a specific issue affecting certain 2024 Tesla Model 3 Performance vehicles. This bulletin provides instructions for addressing minor oil loss that can occur through the Rear Drive Unit (RDU) breather.

The SB-24-40-008 communication is crucial for technicians to properly diagnose and correct the condition, ensuring optimal vehicle performance and preventing potential long-term issues associated with the Tesla Model 3 RDU oil loss.

Symptoms of RDU Oil Loss

Owners of affected 2024 Tesla Model 3 Performance vehicles might observe minor oil loss from the Rear Drive Unit (RDU) breather. This is particularly noticeable during high lateral acceleration cornering maneuvers. Technicians may also find oil stains on the rear aero shield during routine service inspections.

Signs of oil loss from the RDU breather often appear as a filmy, dirty residue or streaks. This residue is typically found on the halfshaft, inverter areas, and the top of the rear aero shield.

Correction Codes and Labor Times

Tesla uses specific correction codes to track the labor and procedures involved in addressing this issue. The following codes and estimated times are associated with the repair:

• SB-24-40-008 Not Applicable: 0.00 hours
• S022440008 (Relocate RDU Breather At Customer Request): 2.10 hours
• S032440008 (Oil Loss Not Observed at RDU Breather Area; Relocate Breather): 2.10 hours
• S042440008 (Oil Loss Observed at RDU Breather Area; Relocate Breather, Drain And Fill RDU Oil): 2.64 hours

Important Warnings and Notes

Owners and technicians should be aware of the following critical information:

• WARNING: Always wear appropriate Personal Protective Equipment (PPE), such as cut-resistant gloves and protective eyeglasses, when performing any part of this procedure.
• CAUTION: When cutting the motor bay noise absorber, do not cut completely through the material. Only remove a thin layer to avoid damaging underlying components.
• NOTE: If a customer requests the RDU breather relocation without reporting oil loss, the inspection steps can be skipped.
• NOTE: If an oil leak is detected but is not originating from the RDU breather, correction code S032440008 should be used to ensure proper tracking of parts and labor for the breather relocation.
• NOTE: When draining and filling the RDU gearbox oil, follow the instructions for the 4DU Oil Pump (Remove and Replace) procedure. However, the oil pump itself should not be replaced.

Repair Procedure Summary

The repair for Tesla Model 3 RDU oil loss involves a detailed inspection and relocation of the RDU breather, potentially including an oil drain and fill. The general steps are as follows:

1. Initial Inspection: The LH rear wheel is removed, and the vehicle is raised to inspect the RDU case for oil loss from the breather, particularly around the halfshaft, inverter, and rear aero shield. This inspection uses Service Manual procedure 34015001.
2. Subframe and Noise Absorber Access: The rear subframe is partially lowered (Service Manual procedure 30010231), and the LH rear wheel liner clip and rear motor bay noise absorber are removed (Service Manual procedure 1201010022).
3. Cleaning and Modification: Any oil residue on surrounding components is cleaned with IPA wipes. A 5 cm x 5 cm square is marked and cut from the motor bay noise absorber to prevent the breather from being compressed.
4. Breather Replacement and Modification: The original RDU breather is removed and discarded. A new replacement breather is prepared by removing its cap and then cutting the baffle in half, discarding the top portion. The reworked baffle is then seated into the new breather.
5. Installation of New Breather and Tube: The reworked breather is installed on the RDU. A new breather tube assembly, complete with a cable tie mount, is attached to the RDU breather and routed along the brake line using cable ties.
6. Reassembly and Oil Service: The cable tie mount is secured to the vehicle body, and the rear motor bay noise absorber and wheel liner are reinstalled. If oil loss from the RDU breather was confirmed, the RDU gearbox oil is drained and refilled (Service Manual procedure 4001010032).
7. System Test: The LV power is reconnected (Service Manual procedure 17010400), and a laptop with Toolbox 3 is connected to the vehicle to run the "Oil Pump Low Pressure Test - Rear Drive Unit" routine.
8. Final Steps: The laptop is disconnected, all remaining components are reinstalled, Service Mode is disabled, and a suspension alignment check is performed if necessary.

Required Tools and Parts

Performing the Tesla Model 3 RDU oil loss repair requires specific parts and specialized tools:

Parts Required

• 1870429-00-F: ASY, FDU BREATHER TUBE (Qty 1)
• 1101758-00-A: ASSEMBLY- BREATHER- 3DU (Qty 1)
• 63481: 3/4" x 3/4" Black Nylon 6.6 ORMADUS® 4-Way Adhesive Cable Tie Mounting base (Qty 1)
• 0710214: 8.000" x 0.185" Black Nylon 6.6 Cable Tie (Qty 1)

If Necessary Parts

• 1096865-00-B: FILL/DRAIN PLUG (Qty 1-2)
• 1108214-00-B: OIL PUMP O-RING-HNBR-AS568-142-GREEN-50A (Qty 1)
• 1108211-00-C: OIL PUMP O-RING,HNBR,ID 58X2MM,BLACK,50A (Qty 1)
• 1108210-00-A: OIL PUMP O-RING-HNBR-ID 38X2MM-BLACK,50A (Qty 1)
• 1646886-04-A: LUBRICANT - KAF 1 DU FLUID - 1 LTR QTY (Qty 3)
  • Note: If 1646886-04-A is unavailable, order 1x 1646886-03-A (5 gallons) or 1x 1646886-02-A (55 gallons).

Special Tools

• 1085936-00-A: E18 Torx Low Profile Socket
• 1099645-00-D: FIXTURE, SUBFRAME, MODEL 3/Y/CT
• 1140311-00-A: LEVER LOCK, HV CONNECTOR, MODEL 3
• 1129348-00-B: JUMP START, XP-20 (Heavy Duty)
• 1115247-01-A: Electronic Test Lead, CAT IV 1000V
• 1076921-00-B: INSULATION MULTIMETER; FLUKE 1507
• 1083188-01-B: Digital Multimeter Unit, EXTECH 355
• 1059330-00-B: PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
• 1054720-00-A: 500 LB PORTABLE BENCH
• 1082171-00-A: S-HOOK, BRAKE CALIPER
• 1457016-00-A: SPRING COMPRESSOR, MODEL 3
• 1081765-00-A: 3/4 TON UNDERHOIST STAND
• 1066521-00-A: OTC POWERTRAIN LIFT 1,650lb
• 1785249-00-A: EXTENSION, 1/4" DR, 6", LOCKING, INSULATED
• 1451830-00-A: M3, SKT, EP10, Low Profile, 1/4" Drive
• 1131264-00-A: SWITCHBOX, OIL PUMP, MODEL 3
• 1541474-00-B: Oil Catch/Measure Kit
• 1080559-21-A: WIHA Torque Screwdriver 0.8-5Nm
• 1773092-00-A: DIAGNOSTICS ADAPTER HARNESS ETHERNET
• 1064740-00-A: SCRAPER, RAZOR BLADE

Shop Supplies

• Isopropyl Alcohol (IPA) Wipes
• Paint Pen
• Brake Cleaner
• 000-0474-001: THREADLOCKER, LOCTITE 222, PURPLE

Owner Action

If you own a 2024 Tesla Model 3 Performance and suspect Tesla Model 3 RDU oil loss or observe oil stains around the rear aero shield, it is recommended to contact your authorized Tesla service center. Even if you haven't noticed oil loss but wish to have the RDU breather relocated as a preventative measure, this can be requested. The service center will perform the necessary inspection and repair as outlined in Service Bulletin SB-24-40-008.

NHTSA ID: 11009781