Correction code 40200200601, 40200200602 3.00 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

1. Open the LH front door and lower the LH front window.
2. Open the tailgate.
3. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
4. Connect a laptop with Toolbox to the vehicle. See Toolbox 3 (Connect and Disconnect).
5. Unlock the vehicle Gateway. See Gateway (Unlock).
6. Disconnect Toolbox and remove the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).
7. Select 'High Voltage' via UI
   Note

   Service Mode Plus > High Voltage
8. Select 'Procedures'
   Note

   Lighting Bolt Icon > High Voltage > Procedures
9. Select 'Rear Drive Inverter Replacement'
   Note

   Procedures > Drive-Inverter-Replacement > Rear Drive Inverter Replacement
10. Select ‘Store Boot + App Data and start fluid fill/drain’, click ‘Run’, and allow routine to complete
    Note

    Select 'Close' once complete
11. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
12. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
13. Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
14. Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
15. Remove the rear skid plate. See Skid Plate - Rear (Remove and Install).
16. Remove all items from pockets and ensure not wearing metal items

    

17. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003

    

18. Put on HV insulating gloves and leather over gloves

    

19. Verify no HV - Install amp clamp to RDU HV harness
    Note

    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

    

    

20. Remove leather over gloves and HV insulating gloves
21. Position coolant drain below rear inverter

    

22. Remove RDU coolant hose from rear inverter
    Note

    1x clip, 1x hose clip, Plug both ends, Release clip, Use a long flathead to release clip on hose and release hose

    

    

    

23. Release rear drive unit LV harness clip
    Note

    1 clip

    

24. Release lower portion of rear inverter acoustic cover
    Note

    2x clips

    

    

25. Remove RDU HV harness bracket
    Note

    4x bolts, T30 , 10 Nm

    

    

26. Lower vehicle until tires are touching the ground
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
27. Position coolant catcher below rear drive unit

    

28. Release acoustic cover surrounding RH motor mount
    Note

    5x clips, if acoustic cover is present on mount, remove and discard

    

    

    

29. Remove RDU supply hose from rear inverter
    Note

    1x spring clip, Plug both ends after disconnecting

    

30. Release rear inverter coolant hose from gearbox housing
    Note

    1x clip, Rotate hose away from inverter

    

31. Remove coolant catcher from below vehicle
32. Disconnect RDU HV cable from RDU
    Note

    1x connector, Disengage locking tab then release connector body and move aside

    

    

33. Disconnect RDU logic connector
    Note

    1x connector, Release locking tab, Do not get coolant ingress into this connector, Move aside as needed

    

34. Release RDU LV harness
    Note

    1x clip

    

35. Remove bolt securing ground strap to RDU
    Note

    1x bolt, 10mm, 10 Nm

    

    

36. Remove label to access phase out cover bolts
    Note

    Label is one time use, Discard after removal

    

37. Remove the bolts securing the phase out cover
    Note

    2x bolts, EP10, 14 Nm

    

38. Remove RDU phase out cover
    Note

    If cover or O-rings are damaged then replace

    

    

39. Remove phase plugs
    Note

    3x plugs, Discard after removal, Firmly grip plug with needle nose pliers then pull outward, If plugs not present then skip this step

    

    

40. Remove bolts securing phase busbars to RDI
    Note

    3x bolts, 10mm, 11.5 Nm, Fasteners should be reused, If fasteners need to be replaced then follow torque sequence, Tighten to 12.5 Nm then reverse 180 degrees then tighten to 5 Nm

    

41. Release acoustic cover surrounding RH motor mount
    Note

    5x clips, if acoustic cover is present on mount, remove and discard

    

    

    

42. Position jack to support rear drive unit

    

43. Loosen RH motor mount bolt
    Note

    1x bolt, E18, 85 Nm, 1x NVH mass, Revision D subframe will not have NVH mass,16 mm hex bolts cannot be used on Revision D subframe, E18 bolts can be used on all subframes, If mass present then mass must be reinstalled,

    

    

44. Remove bolts securing RH motor mount assembly
    Note

    3x bolts, EP14, 35 Nm + 55 degrees

    

    

45. Remove RH motor mount bolt
    Note

    1x bolt, E18, 85 Nm, 1x NVH mass, Revision D subframe will not have NVH mass, 16 mm hex bolts cannot be used on Revision D subframe, E18 bolts can be used on all subframes, If mass present then mass must be reinstalled

    

    

    

    

46. Remove RH rear motor mount assembly from subframe
    Note

    Acoustic cover sits between mount and subframe,If inverter mount is 1923000-xx-B or older, then replace with 1923000-xx-C or newer

    

    

47. Put on ESD wrist strap and secure it to inverter housing

    

48. Remove bolts securing the RDU inverter to gearbox assembly
    Note

    9x bolts, EP10, 12.5 Nm, Fasteners can be reused

    

    

    

    

49. Remove the inverter from drive unit and drain coolant
    Note

    Take caution to avoid damage to the PCBA

    

    

50. Remove drive inverter arc shield
    Note

    Discard after removal, If FR4 arc shield material is present then it must be replaced with silicone arc shield during reassembly, If silicone arc shield material is present then replace it with new silicone arc shield, FR4 material is rigid plastic, Silicone material is flexible

    

    

51. Place drive inverter onto ESD mat

    

52. Remove ESD wrist strap from old inverter

    

53. Prepare new drive inverter
    Note

    Prepare new drive inverter, Save packaging to MRB old drive inverter, Remove any red protective covers

    

    

54. Secure ESD strap onto new inverter housing

    

    

55. Wipe HV cable lugs to ensure contact surfaces are free of debris
    Note

    Allow 1 minute dry time

    

    

56. Install drive inverter arc shield
    Note

    If FR4 arc shield material was present then it must be replaced with silicone arc shield, If silicone arc shield material was present then replace it with new silicone arc shield, FR4 material is rigid plastic, Silicone material is flexible

    

    

57. Position rear inverter onto drive unit
    Note

    1x bolt, EP 10, Hand tight, 2x guide pins, Maneuver rear inverter into position, Take caution when maneuvering between subframe do not damage the circuit board, Thread in fastener to hold unit in place

    

    

58. Install fasteners securing inverter to gearbox assembly
    Note

    9x bolts, EP10, Install hand tight, Torque at a later step

    

59. Torque fasteners securing inverter to gearbox assembly
    Note

    9x bolts, EP10, 12.5 Nm, Torque two fasteners nearest alignment dowels first

    

60. Install bolts securing phase busbars to RDI
    Note

    3x bolts, 10mm, 11.5 Nm, Fasteners should be reused, If fasteners need to be replaced then follow torque sequence, Tighten to 12.5 Nm then reverse 180 degrees then tighten to 5 Nm

    

    

61. Install RDU phase out cover
    Note

    Updated cover must be installed, If cover or O-rings are damaged then replace

    

    

    

    

62. Install bolts securing the RDU phase out cover
    Note

    2x bolts, EP10, 14 Nm

    

63. Install phase out cover warning label
    Note

    One time use, install new label

    

64. Remove ESD wrist strap from inverter

    

65. Take old inverter and prepare for MRB, Label properly for return or disposal
    Note

    Use ESD wrist strap, Label inverter for MRB and return to packaging, Secure any protective red caps, Return or dispose of packaging through proper channels, Label the part as MRB

    

    

    

66. Install leak test adapter plug to 12V connector at inverter - placeholder

    

67. Install leak test adapter to RDU HV connector - placeholder

    

    

68. Connect regulator to adapter at HV connector

    

69. Close both valves on the regulator test tool

    

70. Connect regulator to air supply

    

71. Turn on regulator and open valve closest to regulator

    

72. Set regulator to 1 psi

    

73. Open the 2nd valve to inject air into the penthouse
    Note

    Close valve when pressure reaches 1 psi and stable

    

74. Wait 45 seconds for pressure to settle
75. Record start pressure valve
76. Wait 60 seconds for test
77. Record end pressure valve
    Note

    If pressure did not drop more than 0.04 psi, continue to next step. If pressure dropped more than 0.04 psi, then inspect for leaks.
78. Disconnect air supply from regulator tool

    

79. Disconnect regulator from leak test adapter at HV connector

    

80. Remove leak test adapter from HV connector

    

81. Remove leak test adapter plug from 12V connector at inverter - placeholder

    

82. Position RH side motor mount
    Note

    Maneuver between drive unit and subframe, if acoustic cover is present on mount, remove and discard,If inverter mount is 1923000-xx-B or older, then replace with 1923000-xx-C or newer

    

    

83. Hand tighten bolts securing RH rear motor mount to inverter and subframe
    Note

    4x bolts, E14, 35 Nm + 55 degrees, 1x bolt, E18, 85 Nm, 1x NVH mass, Revision D subframe will not have NVH mass, If mass present then mass must be reinstalled, Torque at later step

    

    

    

    

84. Torque bolts securing RH motor mount to rear drive unit
    Note

    4x bolts, E14, 35 Nm + 55 degrees, Follow torque sequence

    

    

    

85. Torque RH rear motor mount to subframe
    Note

    1x bolt, E18, 85 Nm, 1x NVH mass, Revision D subframe will not have NVH mass,16 mm hex bolts cannot be used on Revision D subframe, E18 bolts can be used on all subframes, If mass present then mass must be reinstalled,

    

    

86. Remove jack stand from supporting rear drive unit assembly

    

87. Secure RH side acoustic cover
    Note

    5x clips, Secure above clips and remaining from below

    

    

88. Install bolt securing ground strap to RDU
    Note

    1x bolt, 10mm, 10 Nm

    

    

89. Secure RDU LV harness
    Note

    1x clip

    

90. Connect RDU HV connector
    Note

    1x connector, Inspect connector housing on harness side and inverter side for presence of coolant or any debris, Engage locking tab

    

91. Position coolant catcher below rear drive unit

    

92. Secure rear inverter coolant hose to gearbox housing
    Note

    1x hose clip

    

93. Install rear inverter coolant supply hose to inverter
    Note

    1x spring clip, Remove plugs from both ends, Perform push-pull test

    

94. Raise vehicle fully
95. Secure lower acoustic cover clips
    Note

    2x clips

    

    

96. Secure lower acoustic cover clips
    Note

    2x clips

    

    

97. Secure RDU LV harness clip
    Note

    1x clip

    

98. Connect RDU logic connector
    Note

    1x connector, Inspect connector housing on harness side and inverter side for presence of coolant or any debris, Verify lever is fully engaged

    

99. Position coolant drain below rear inverter

    

100. Install coolant hose onto rear inverter lower fitting
     Note

     1x spring clip, Remove plugs from both ends, Perform push-pull-push test

     

101. Remove coolant drain container from underneath vehicle
102. Install RDU HV harness bracket
     Note

     4x bolts, T30 , 10 Nm

     

     

103. Secure RDU header connector to ancillary
     Note

     1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

     

     

104. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
105. Install the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
106. Perform cooling system vacuum fill. See Cooling System (Vacuum Refill).
107. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
108. Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete
     Note

     Select 'Close' once complete
109. Run ODIN routine PROC_PMR_X_RESTORE-DATA-BOOT-AND-WRITE-DRIVE-TYPEvia Toolbox:(link)
110. Run ODIN routine PROC_DIR_X_RESTORE-DATA-APPvia Toolbox:(link)
111. Run ODIN routine PROC_EGGRIGHT3_X_THERMAL-COOLANT-AIR-PURGE-STARTvia Service Mode Plus:
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
     via Toolbox:(link)
112. Run ODIN routine TEST-SELF_EGGRIGHT3_X_THERMAL-PERFORMANCEvia Service Mode:
     • Thermal ➜ Actions ➜ Test Thermal Performance
     • Thermal ➜ Coolant System ➜ Test Thermal Performance
     via Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
     via Toolbox:(link)
113. Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn
     Note

     Use safety stanchions to section off vehicle before driving vehicle on a lift
114. Raise vehicle partially and lower lift onto locks
     Note

     Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
115. Run ODIN routine PROC_DIR_X_RESOLVER-ERROR-LEARNvia Service Mode Plus:Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Resolver Error Learnvia Toolbox:(link)
116. Remove safety stanchions from around vehicle after resolver learn is completed
     Note

     Remove all stanchions after vehicle is finished with the resolver error learn
117. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
118. Close the tailgate.
119. Raise the LH front window and close the LH front door.
120. Perform test drive
     Note

     Perform a validation test drive after repairDrive a minimum speed of 25mph, Drive in a straight line and check for excessive pull, Verify the steering wheel is centered when vehicle is driving straight, Determine whether an alignment is recommendedAdd correction code 00040100 as needed