LDU removal from a Toyota RAV4 @ youtube (has overlap with other brands incl Tesla)
LDU disassembly @ youtube (remove inverter cover; split gearbox; remove gears; various inspections)
LDU disassembly @ youtube (remove rotor; remove manifold; cleaning; found leaking *inner* seal)
CarRepairVideos’ alternative end shield removal method @ youtube (Master Service in Ukraine)
From TMC:
Inverter Temp Sensor Connector Disassembly
Tapping out the Primary Shaft
Removing Motor End shield
From Tesla Large Drive Unit (LDU) Motor Teardown and maintenance - Page 6 - openinverter forum (and next next post):
Removing stuck rotor (READ UPDATE section of post on damaging the hybrid bearing)
👉 The coolant seal can be removed using a "seal puller". This is way less destructive than using a dremel tool. See also other removal techniques in the
description below this video.
👉 Reluctor wheel removal: You can use a "wiper arm puller" as described description below this video. Or create DIY tool as done by Muehlpower.
Inner seal replacement @ youtube.
Repacking the hybrid ceramic rotor bearings with grease @ youtube. Some details:
Fill fraction references: "[...] the quantity should never exceed 30% of the free space in the bearing. In high-speed applications, this quantity should be less than 30%." from: plantengineering.com | 15% fill fraction @ SKF
Grease selection chart @ SKF
SKF online grease selection tool: Input = application profile (“electric motor”)
SKF online grease selection tool: Input “application conditions” (selected the 6007 hybrid bearings)
SKF online grease selection tool result/output:
SKF's 6007 hybrid bearing comes standard with: "Wide temperature range grease (ester oil based and polyurea thickened)"
Notes:
do not mix different greases! So clean bearing thoroughly first.
polyurea based thickener is preferred for electric motors
polyurea based thickener: better life expectancy 3-5x according to Machine Lubrication
LGHQ 2 grease is intended for auto-lube machines
Replacing the coolant seal @ youtube
👉 Vital (❗) PTFE seal installation tips - Garage Gurus/Payen seals @ youtube (applied to ICE car as example)
👉if shaft is worn out too much: add a SKF speedi sleeve 99114 | example | youtube
"breaking in" a rotor after repacking the bearings @ youtube
If rotor spline *or* water seal shaft contact region is worn out: Spray weld and re-machine the spline: youtube | youtube
Seized (rusted stuck) rotor; rotor spline damage -Rich Rebuilds @ youtube
Seized rotor; stripped spline; flooded inverter electronics - QC Charge @ youtube
Flooded inverter - QC Charge @ youtube
Gearbox primary shaft bearing fluting damage - CarRepairVideos @ youtube (may be unrelated to coolant leak)
putting the LDU back together @ youtube (see torque specs in figures below for easy reference)
👉Pro tip: Clean off the old silicone from the bolts using gasoline. This will save you a lot of brushing.
leak test before mounting in car + final LDU assembly steps @ youtube
mounting LDU into Toyota RAV4 EV @ youtube
online remote diagnostics / troubleshooting @ youtube (example uses Toyota, but can be applied too to Tesla, Mercedes, etc)
See LDU Specs
CarRepairVideos' many LDU repairs @ youtube (turn on autocaptions and set translate to english) - world class key EV repair info! The actual business behind
these videos is Master Service Garage
QC Charge's LDU removal @ youtube (Toyota RAV4 EV only)
Nathan Schenk’s LDU rebuild @ myrav4ev | Google docs | google photos | TMC
Paul Young’s Porsche / LDU retrofit @ openinverter.org | youtube
Kent Patterson’s LDU mod project @ youtube | youtube (used for speed boat retrofit)
Shane Stang's LDU rebuild @ TMC
EV-Services' (Norway) professional rebuild @ youtube (EVServices.no; uses 2000 grit sandpaper; note the bearing puller!)
thewalkz’ LDU rebuild case @ TMC
InspireEV's LDU disassembly process @ youtube (no rotor removal)
Dan K's LDU rebuild snapshot @ TMC
Shane's LDU *interter* cooling leak repair attempts @ TMC