01/04/2024 13:57:12

Bushing - Rear Drive Unit - RH (Remove and Replace)

Correction code 40012402 5.10 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT 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. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2024-01-12: Updated torque figure for the bolt that attaches the ground strap to the RDU from 6 Nm to 10 Nm.
  • 2023-10-24: Updated torque figure for rear upper fore link to knuckle from 76 Nm to 84 Nm.
  • 2023-08-23: Updated EPB Service Mode reference.
  • 2023-06-09: Added shear plate small bolts torque figure for Structural Pack vehicles.
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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Open all four doors and lower the LH front window.
  2. Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
  3. Move LH front seat forward
  4. Move RH front seat forward
  5. Remove 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Lift front edge of seat cushion upward to release foam from frame
  6. Open hood
  7. Remove rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  8. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off
  9. Disconnect 12V negative terminal and first responders loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
  10. Remove all items from pockets and ensure not wearing metal items
  11. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
  12. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  13. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
  14. Remove the ancillary bay probe lid cover from the ancillary bay cover
  15. Verify no high voltage
    Informational PurposesAn informational icon, calling your attention
    Note
    Make 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
  16. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Confirm no visual damage present, Replace gasket if damage is found
  17. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
  18. Remove HV insulating gloves
  19. Remove LH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  20. Remove RH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  21. Loosen RH rear wheel
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    Note
    5x nuts, 21mm, 175 Nm
  22. Loosen LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  23. Raise vehicle partially and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to a 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
  24. Remove LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  25. Remove RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  26. Remove RH rear brake caliper from knuckle and hang from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E18, 83 Nm, Discard bolts after removal
  27. Remove LH rear brake caliper from LH rear knuckle and hang from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E18, 83 Nm, Discard bolts after removal
  28. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  29. Remove mid aero shield
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    Note
    11x bolts, 10mm, 5 Nm
  30. Remove bolts securing rear diffuser to body
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    Note
    9x bolts, 10mm, 4 Nm
  31. Remove clips securing rear diffuser to body and remove from vehicle
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    Note
    6x push clips
  32. Remove LH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  33. Remove RH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  34. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  35. Install spring compressor onto LH rear coil spring
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    Note
    Reference photos for clarification
  36. Unbolt LH strut from body at top mount
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    Note
    2x bolts, 15mm, 41 Nm
  37. Install spring compressor onto RH rear coil spring
  38. Unbolt RH strut from body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm
  39. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  40. Disconnect RH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  41. Remove RH side 12V subframe harness clip from body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  42. Disconnect LH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  43. Remove LH side 12V subframe harness clip from body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  44. Remove the nut that attaches the RDU ground strap to vehicle.
  45. Remove nut securing LH rear stabilizer bar end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
  46. Remove stabilizer bar from LH rear end link
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
  47. Remove nut securing RH rear stabilizer bar end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
  48. Remove stabilizer bar from RH rear end link
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
  49. Position support stand to support front portion of rear subframe
  50. Remove bolts securing stabilizer bar to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, 11mm, 30 Nm, Discard after removal
  51. Lower support stand and remove stabilizer bar from vehicle
  52. Remove support stand from under vehicle
  53. Release clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  54. Release LH side hose clip from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  55. Release RH side hose clips from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  56. Release clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  57. Remove lower bolts securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm
  58. Remove upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  59. Remove upper bolts securing rear battery enclosure skid plate from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  60. Remove rear battery enclosure skid plate from HV battery pack
  61. Position coolant drain container underneath LH rear of HV battery
  62. Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs
  63. Position coolant drain container underneath LH RDU area
  64. Disconnect RDU inverter inlet tube from fluid coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Plug the hose end and the fluid coupling
  65. Position coolant drain underneath RH rear of HV battery
  66. Disconnect coolant outlet hose to rear PT return hose and plug hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary
  67. Remove coolant drain container from underneath vehicle
  68. Remove nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  69. Disconnect RDU HV cable from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
  70. Place subframe lifting tool into position underneath rear subframe
  71. Connect air supply to subframe lifting tool
  72. Raise subframe lifting tool to support rear subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    3x straps, Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure, Lower the vehicle if necessary, Recommend assistance
  73. Remove smaller fasteners for LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
  74. Remove large bolt securing LH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard after removal
  75. Remove smaller fasteners for RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
  76. Remove large bolt securing RH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard after removal
  77. Remove LH rear bolt securing subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Discard after removal
  78. Remove RH rear bolt securing subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Discard after removal
  79. Lower subframe lifting tool to remove subframe from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage components while lowering subframe
  80. Disconnect air supply from subframe lifting tool
  81. Move the subframe lifting tool and subframe away from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise vehicle if necessary
  82. Remove coolant inlet hose clip from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  83. Remove coolant inlet hose from subframe
  84. Remove bolt securing RDU HV cable bracket to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  85. Disconnect RDU HV cable from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Red locking tab
  86. Remove RDU HV cable from subframe
  87. Perform RDU diode test
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify RDU HV cable is disconnected from HV battery. Use a multimeter in diode mode, with the positive DMM probe to B- of the inverter and the negative probe to B+. Pin #1 on HV cables is B- and Pin #2 is B+. MOSFET acceptable diode reading:1.0 - 2.0 V. IGBT acceptable diode reading 0.45 - 2 V (if you get OL or > 2V for a reading you most likely have the probes installed the wrong way around)
  88. Remove the bolt that attaches the ground strap to the RDU assembly.
  89. Remove LH rear wheel speed sensor from LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  90. Remove grommet securing LH rear wheel speed harness to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  91. Remove nut and bolt securing LH rear upper aft link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm
  92. Remove nut and bolt securing LH rear upper fore link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm
  93. Remove nut and bolt securing LH rear toe link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm
  94. Disconnect RDU 12V connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  95. Remove RDU 12V harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  96. Disconnect resolver connector from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x clips
  97. Disconnect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
  98. Remove RH rear wheel speed sensor from RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  99. Remove grommet securing RH rear wheel speed sensor to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  100. Remove nut and bolt securing RH rear upper aft link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm
  101. Remove nut and bolt securing RH rear upper fore link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm
  102. Remove nut and bolt securing RH rear toe link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm
  103. Release LH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
  104. Remove LH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Install axle seal plug
  105. Release RH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
  106. Remove RH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Install axle seal plug
  107. Position drive unit stand underneath gantry
  108. Attach drive unit sling tool to drive unit
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    Note
    3x hooks
  109. Secure drive unit sling to gantry
  110. Raise sling so there is slight tension on the cables
  111. Remove LH bolt securing drive unit to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm
  112. Remove RH bolt securing drive unit to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm
  113. Remove bolt securing rear of drive unit to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm
  114. Raise sling to lift drive unit out of subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Carefully guide halfshafts away from FDU while lifting
  115. Move subframe and lifting tool from underneath drive unit
  116. Position empty drive unit crate below drive unit
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    Note
    Use pallet if no empty crate available
  117. Lower drive unit into drive unit crate
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    Note
    Use pallet if no empty crate available
  118. Lower sling to release tension on the cables
  119. Remove drive unit sling from gantry
  120. Remove drive unit sling tool from drive unit
  121. Attach RDU engine stand adapter to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 15mm, 3x nuts, 15mm, Hand tight, Recommend assistance
  122. Attach gantry hook to RDU adapter
  123. Using gantry, lift RDU assembly for installation onto engine stand
  124. Move engine stand into position
  125. Install RDU adapter to engine stand
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 18mm, 4x nuts 18mm
  126. Install bushing removal tool on RH front bushing
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    Note
    2x nuts, 22mm, use cups "C", "A", and "G" to drive bushing out, always drive on the bearing side and hold the opposite
  127. Press bushing out from casting
    Informational PurposesAn informational icon, calling your attention
    Note
    Set up bushing removal tool with the bearing away from the drive unit, the threaded rod is very close to RDU components and damage to the tool/RDU may occur if the bushing is drive out from the drive unit side
  128. Separate bushing tool and remove bushing

Install

  1. Prepare to install new bushing
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    Note
    Before installation check whether the bushing is intact and spray lubricant on the outside of the bushing
  2. Setup tool to press in new bushing
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    Note
    2x nuts, 22mm, use cup "E" and "D", always drive on the bearing side and hold the opposite
  3. Press in new bushing
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    Note
    Ensure keyway is facing towards the top of the drive unit, parallel to the drive unit
  4. Separate bushing tool and remove from drive unit
  5. Using the gantry hook, support the RDU engine stand adapter, applying tension
  6. Remove the bolts securing RDU engine stand adapter to engine stand and move engine stand away
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 18mm, 4x nuts, 18mm
  7. Lower RDU and engine stand adapter onto crate
  8. Remove gantry hook from RDU adapter and move aside
  9. Remove RDU engine stand adapter from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 15mm, 3x nuts, 15mm
  10. Attach drive unit sling tool to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    3x hooks
  11. Secure drive unit sling to gantry
  12. Raise drive unit out of drive unit crate
  13. Move subframe and lifting tool underneath drive unit
  14. Lower sling to install rear drive unit into subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Carefully guide halfshafts away from FDU while lowering
  15. Install rear bolt securing drive unit to subframe, hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm, Torque at a later step
  16. Install RH bolt securing drive unit to subframe, hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm, Torque at a later step
  17. Lower sling to release tension on the cables
  18. Remove drive unit sling from gantry
  19. Remove drive unit sling tool from drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    3x hooks
  20. Torque motor mount bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 18mm, 80 Nm
  21. Install LH halfshaft to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
  22. Install RH halfshaft to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
  23. Secure clips holding coolant outlet hose to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  24. Secure coolant outlet hose to drive unit cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  25. Secure inverter to cooler hose to cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  26. Secure clips holding inverter to coolant hose to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  27. Secure inverter to cooler hose to inverter
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  28. Connect resolver connector to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x clips, Engage locking tab
  29. Connect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  30. Install RH rear toe link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
  31. Install RH rear upper fore link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm, Recommend assistance, Torque at later step
  32. Install RH upper aft link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm, Recommend assistance
  33. Loosely install RH rear lower fore link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 18mm, 76 Nm, Torque at later step
  34. Install grommet securing RH wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  35. Install bolt securing RH wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  36. Install RDU 12V harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  37. Install RDU 12V connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  38. Install the bolt that attaches the ground strap to the RDU assembly.
  39. Install LH rear toe link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
  40. Install nut and bolt securing LH rear upper fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm, Torque at later step
  41. Install LH rear upper aft link to LH rear knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm
  42. Loosely install LH rear lower fore link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Torque at later step
  43. Install grommet securing LH rear wheel speed sensor harness to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  44. Install LH rear wheel speed sensor to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  45. Install RDU HV cable into position on the rear subframe
  46. Connect RDU HV cable to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Install HV connector lever lock to RDU HV cable connector, Align connector to RDU then remove HV connector lever lock before fully latching connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position
  47. Install bolt securing RDU HV cable bracket to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  48. Install coolant inlet hose into subframe
  49. Remove hose plugs and connect coolant inlet hose to rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
  50. Install coolant inlet hose clip to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  51. Position subframe lifting tool and subframe under vehicle
  52. Connect air supply to subframe lifting tool
  53. Raise drive unit and subframe into position
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage components while raising subframe
  54. Install RH rear bolt securing rear subframe to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
  55. Install LH rear bolt securing rear subframe to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
  56. Install bolt and shear plate to LH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
  57. Install bolts securing LH rear shear plate to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
  58. Install bolt and shear plate to RH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
  59. Install bolts securing RH shear plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
  60. Torque bolts securing shear plates to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
  61. Torque bolt securing subframe and LH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm
  62. Torque bolt securing subframe and RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm
  63. Torque bolt securing RH rear of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
  64. Torque bolt securing LH rear of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
  65. Install clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  66. Install clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  67. Lower rear subframe lifting tool from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify yellow safety straps are removed from subframe
  68. Disconnect air supply from subframe lifting tool
  69. Remove subframe lifting tool from underneath vehicle
  70. Connect RDU HV cable to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
  71. Install nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  72. Position coolant drain underneath RH rear of HV battery
  73. Remove hose plugs and connect coolant outlet hose to rear PT return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary
  74. Position coolant drain container underneath LH rear of HV battery
  75. Remove plugs and connect RDU inverter inlet hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  76. Remove coolant drain container from underneath vehicle
  77. Position rear battery enclosure skid plate to HV battery for installation
  78. Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, Torque at later step
  79. Install upper nut securing rear battery enclosure skid plate hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Torque at later step
  80. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  81. Torque bolts securing HV battery and rear skid plate to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  82. Torque upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  83. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  84. Install RH side hose clips to rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  85. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  86. Place stabilizer bar into position for installation and raise stand to support stabilizer bar
  87. Install bolts securing stabilizer bar to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, 11mm, 30 Nm, Install new patch bolts
  88. Position LH rear end link into stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
  89. Install nut securing LH rear end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
  90. Position RH rear end link into stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
  91. Install nut securing RH rear end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
  92. Remove support stand from under vehicle
  93. Install the bolt that attaches the RDU ground strap to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  94. Install LH side 12V subframe harness clip to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  95. Connect LH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  96. Install RH side 12V subframe harness clip to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  97. Connect RH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  98. Install rear diffuser to rear fascia assembly and secure clips to body
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips
  99. Apply Loctite 222 onto rear diffuser bolts and install bolts securing rear diffuser to body
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 4 Nm
  100. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  101. Install bolts securing RH damper to body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm
  102. Install RH rear brake caliper onto knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
  103. Remove bolt securing RH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  104. Install hub jack adapter onto RH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  105. Position and raise support stand to simulate RH rear suspension at ride height
  106. Use rear ride height torque gauge to verify RH suspension is set to ride height specification
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to slightly adjust stand or compression tool
  107. Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height
    Informational PurposesAn informational icon, calling your attention
    Note
    Distance should be 427 mm
  108. Torque bolt securing RH rear toe link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  109. Torque bolt securing RH rear upper fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 84 Nm, Mark with paint pen
  110. Torque bolt securing RH rear lower fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  111. Torque bolt securing RH rear upper aft link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 134 Nm, Mark with paint pen
  112. Remove support stand from underneath RH suspension
  113. Remove hub jack adapter from RH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  114. Install bolt securing RH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  115. Remove spring compressor from RH rear coil spring
  116. Install bolts securing LH damper to body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm, Apply pressure at top of damper to push down and clear wheel liner
  117. Install LH rear brake caliper onto LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
  118. Remove bolt securing LH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  119. Install hub jack adapter onto LH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  120. Position and raise support stand to simulate LH rear suspension at ride height
  121. Use rear ride height torque gauge to verify LH suspension is set to ride height specification
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to slightly adjust stand or spring compressor tool
  122. Measure from bottom of quarter panel to center of axle as a secondary check to make sure LH suspension is set to ride height
    Informational PurposesAn informational icon, calling your attention
    Note
    Distance should be 427 mm
  123. Torque bolt securing LH rear toe link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  124. Torque bolt securing LH rear upper fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 84 Nm, Mark with paint pen
  125. Torque bolt securing LH rear lower fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  126. Torque bolt securing LH rear upper aft link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 134 Nm, Mark with paint pen
  127. Remove support stand from underneath LH rear suspension
  128. Remove hub jack adapter from LH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  129. Install bolt securing LH rear rotor to LH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  130. Remove spring compressor from LH rear coil spring
  131. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  132. Install LH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  133. Install RH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  134. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 5 Nm
  135. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  136. Install LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  137. Install RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  138. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  139. Torque LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  140. Torque RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  141. Install RH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  142. Install LH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  143. Remove coolant bottle cap
  144. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  145. Connect first responder loop and 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
  146. Install 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
  147. Move RH front seat to original position
  148. Move LH front seat to original position
  149. Press and hold park button to release EPB service mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove wheel chocks if necessary
  150. Connect to vehicle using Toolbox 3.0
  151. Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
  152. Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    ’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
  153. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  154. Install coolant bottle cap
  155. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  156. Close hood
  157. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  158. Raise all four windows
  159. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If 12V is powered up, Unlatch rear doors before closing
  160. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  161. Check tire pressures
    Informational PurposesAn informational icon, calling your attention
    Note
    4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar
  162. Verify the alignment slip/turn plates are locked
  163. Drive vehicle onto alignment rack
  164. Pull vehicle forward and stop ~ 0.5 ft before turn plates to allow for rolling compensation
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift to park
  165. Shift to park
  166. Install wheel chocks
    Informational PurposesAn informational icon, calling your attention
    Note
    Place chocks on both sides of the driver's side rear tire
  167. Latch the driver seat belt to buckle
  168. Latch LH front door and place vehicle into neutral
    Informational PurposesAn informational icon, calling your attention
    Note
    Careful not to slam the door while latch is engaged
  169. Raise alignment rack partially and lower to lock position
  170. Install alignment heads onto wheels
    Informational PurposesAn informational icon, calling your attention
    Note
    4x alignment heads
  171. Enter vehicle information to alignment machine
  172. Perform rolling compensation
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the wheel chocks from the LH rear tire and push the back of the tire to roll vehicle forward. Reinstall wheel chocks once vehicle is in position
  173. Unlock alignment slip/turn plates
  174. Verify chassis height measurement tool is calibrated
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust if necessary, Measure height of tool and adjust reading to match
  175. Perform ride height measurement
    Informational PurposesAn informational icon, calling your attention
    Note
    Measure the ride height 75mm inward of the HV battery ski hole at each corner, If using ballast bags, move the front seats as necessary to achieve ride height spec, See Service Manual for ride height specifications
  176. Apply brake pedal depressor
  177. Perform caster sweep and install steering wheel holder and level tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If camber and caster are out of specification, perform necessary camber and caster adjustment
  178. Verify alignment reading is within specification and print vehicle summary
  179. Remove alignment heads from wheels
    Informational PurposesAn informational icon, calling your attention
    Note
    4x alignment heads
  180. Remove brake pedal depressor
  181. Lock alignment slip/turn plates
  182. Lower the alignment rack to ground
  183. Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
  184. Unlatch LH front seat belt
  185. Remove wheel chocks
  186. Remove vehicle from alignment rack
  187. Perform test drive
    Informational PurposesAn informational icon, calling your attention
    Note
    Per current FRT (00040100) 0.3 hrs, If alignment was adjusted verify tracking, If DAS components were adjusted verify operation, If brakes were serviced perform burnishing