Revolt Systems Rotor Seal Bypass Manifold “The Fix”
(A ects all Tesla Large Drive Units)
This procedure addresses the notorious rotor seal issues present in all Tesla Large Drive Units
(LDU). The seal and sealing surface degrade and allows coolant to leak into the stator windings
and inverter. This causes isolation issues, inverter failure and in some cases complete motor
seizure. If the rotor seal has not yet leaked, this kit will eliminate all risk of rotor seal failure in
the future.
The purpose of the seal is to allow heated coolant from the rotor to pass through the external
coolant line across to the gearbox to heat up the transmission uid and reduce condensation in
cold environments. In almost all applications this is unnecessary as anything but the shortest
driving distances will heat up the transmission su ciently to ful ll the same purpose. This kit
eliminates this redundant feature, and therefore eliminates the Achilles heel of these otherwise
extremely reliable motors.
Tools Required:
10mm socket/wrench
Small pry bay
5mm drill bit (or standard equivalent)
Silicone sealant (Permatex Ultra Black 82180 recommended)
O-ring grease
With the LDU removed
from the vehicle, rst
remove the three 10mm
bolts securing the external
coolant line and remove
the coolant line. Carefully
remove an o-ring from the
coolant line and set it
aside. You will use it later
on the blanking piece.
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Remove the two 10mm bolts
securing the encoder and coolant
tting and remove both components
from the LDU. These components
will be re-used.
Remove the six 10mm bolts
securing the rotor seal manifold.
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Use a pry-bar to carefully remove the
rotor seal manifold. There are two
convenient pry points shown in these
photos, but take care to pry it o evenly
and as square as possible to the drive
unit.
A small amount of coolant will be present
when the manifold is removed. This is
normal. If you nd rust and corrosion on
the encoder wheel and rotor bearing, this
is an indicator that the rotor seal has
already begun leaking. In this case your
motor may be salvageable or it may need
to be rebuilt. Revolt Systems works with
several specialists who are able to rebuild
these motors. If you believe your rotor
seal has been leaking, contact
[email protected] with photos and
your location, and we may be able to
refer you to a rebuilder.
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The two lower bolt holes are usually full
of silicone from factory assembly. If left in
place, this will cause the bolts to bind
during reassembly and strip out the
threads. Use a 5mm drill by hand to
remove the silicone from these holes. Do
not use a power drill as you risk
damaging the threads. Inspect the o-ring
on the drive unit and ensure it is free from
any debris and that it is seated in its
groove. Do not apply any silicone sealant
to the o-ring.
Apply a thin bead of silicone sealant
around the new Rotor Seal Bypass
Manifold as shown. Apply a thin lm of
o-ring grease to the new Rotor Seal
Bypass Manifold as shown.
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Install the new Rotor Seal Bypass
Manifold, taking care to seat it correctly
rst time to avoid dislodging the o-ring.
Loosely screw in all the 10mm bolts.
Once all bolts are in position, torque
them to 8Nm in a criss-cross pattern.
If the bolts start to get tight before
they are fully seated, STOP, and see if
the bolt hole still has old silicone stuck
in it. These threads are easily stripped,
especially the lower two.
Apply a small amount of o-ring grease to
the encoder and water tting o-rings and
install them in the new Rotor Seal
Bypass Manifold. Torque the bolts to
8Nm.
Take the o-ring from the external coolant
line and install it on the new block-o
piece. Apply a small amount of o-ring
grease to the o-ring. Install the block-o
piece as shown and torque the bolt to
8Nm. Ensure the black AN cap is
torqued appropriately.
The Fix is now complete!
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