05/10/2023 09:06:05

Subframe Assembly - Front (2nd Generation) (Dual Motor) (Remove and Install)

Correction Code 30010331

  • 2023-09-12: Updated hyperlinks.

This procedure is for Dual Motor vehicles built between April 10, 2016 and April 24, 2019.

For other generation front subframe assemblies, see also:

Special tools required for this procedure:

  • 1021241-00-B - Subframe Fixture, Rear, MDLS
  • 1021242-00-C - Subframe Fixture, Front Jig - MDLS

    or

  • 1063646-00-A - Model S/X Legacy Subframe Lift Fixture
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.
  • 2023-10-05: Added alternative special tool.

Removal

  1. Center the steering wheel, and then install the steering wheel holder. Make sure that the front road wheels are in a straight ahead position.
  2. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  3. Disconnect 12V power. See Disconnect 12V Power.
  4. Remove the front wheels. Wheels - Axle Set (Remove and Install).
  5. Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install).
  6. Remove the front skid plate. Skidplate - Front (Remove and Replace).
  7. Remove the clip (x1) that attaches the battery coolant pump 2 hose to the front subframe.
  8. Remove the powertrain coolant pump 2 harness clip from the front subframe, and then remove powertrain coolant pump 2. See Powertrain Coolant Pump 2 (Remove and Replace).
  9. On each side of the vehicle, release the bolts (x2) that attach the stay bar (torque 11 Nm).
  10. Remove the skid bar from the front subframe. See Skid Bar - Front Subframe (Remove and Replace).
  11. Remove the nuts (x2) that attach the ABS modulator pump to the subframe, and then release the ABS modulator pump from the rubber mounting. See ABS Modulator Assembly (Remove and Replace).
  12. Remove the forward bolt that attaches the radiator bypass 3 way coolant valve to the subframe bracket (torque 5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The rear bolt is removed in a later step, as it is only accessible from above the vehicle.
  13. Partially lower the vehicle to a comfortable working height.
  14. Remove the bolts (x3) that attach the chiller to the front subframe (torque 5 Nm).
  15. Remove battery coolant pump 1 from the subframe bracket. See Battery Coolant Pump 1 (1st Generation) (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    The coolant hose is still between the front subframe and the stabilizer bar.
  16. Disconnect the steering rack connectors (x2) from the steering rack.
  17. Remove the bolts (x2) that attach the air suspension pump bracket to the front subframe (torque 5.5 Nm).
  18. Remove the rear bolt that attaches the radiator bypass 3 way coolant valve to the front subframe (torque 5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The forward bolt was removed from above the vehicle in a prior step.
  19. Place a metal rod or similar across the top of the front frame rails to support removed accessories.
  20. Raise the vehicle to a comfortable working height.
  21. On both sides of the vehicle, loosen but do not remove the tie rod ends. See Tie Rod End - LH (Remove and Replace).
  22. Fully raise the vehicle to a comfortable working height.
  23. On each side of the vehicle, remove and discard the nut (x1) that attaches the stabilizer bar to the stabilizer bar end links. See Link - Stabilizer Bar - Front - LH (Remove and Replace).
  24. On both sides of the vehicle, remove the bolt (x1) and nut (x1) that attach the front shock absorber to the rear lower control arm (torque 140 Nm).
  25. Remove and discard the LH and RH lower control arm nuts (x2) and washers (x2) (torque 196 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To prevent ball joint damage, always hold the ball joint pin with a wrench while loosening or tightening the lock nut.
  26. Remove the bolt that attaches the lower intermediate shaft to the steering rack, and then slide the shaft off of the rack. See Intermediate Shaft - Steering Column - Lower (RWD) (Remove and Replace) or GUID-EC4B6D7A-F083-4CB7-9122-B2119D58A70D.html.
  27. Remove and discard the bolts (x4) that attach the front subframe to the bumper carrier:
    • Composite carrier: 7.5 Nm
    • Magnesium carrier: 11 Nm
  28. Install the front subframe jig onto the subframe fixture.
  29. Install the locating pins in the appropriate location.
    1 Rear wheel drive
    2 Dual motor
  30. Have an assistant lower the vehicle. Guide the front subframe onto the fixture.
  31. On each side of the vehicle, remove the bolts that attach the front subframe to the chassis.
    • Forward bolts (x2) (torque 115 Nm)
    • Rear bolts (x2) (torque 115 Nm)
  32. Lower and tilt the subframe back to remove it from the carrier, and then move the front subframe away from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect coolant hoses and the chiller by feeding them past the stabilizer bar.
  33. Noting the number of turns required, unscrew the LH and RH tie rod ends that were loosened in a previous step, and then remove them from the vehicle.
  34. Remove the bolts (x3) that attach the steering rack assembly to the front subframe, and then remove the steering rack from the subframe (torque 175 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    A washer might be located between the steering rack and the subframe. Retain and use this washer during reinstallation of the steering rack.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only use cleaning agents and solvents in a well-ventilated area.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all patchbolt(s).
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all nylon-insert locknuts.
Informational PurposesAn informational icon, calling your attention
Note
Clean the affected areas before installation.

Observe the following:

  • Align the witness marks on the chassis and subframe.
  • Make sure that all subframe fixing bolts are started before attempting to tighten.
  • Align the suspension components to the subframe and set the cams to the previously marked positions. Do not fully tighten at this time.
  • After installing all suspension components, pull on the LH and RH front inner halfshaft cups to confirm that the circlip is locked into place. If the halfshaft detaches from the drive unit then reinstall the halfshaft and then test that it is fully seated. If reinstalling the halfshaft:
    • Take care not to damage or displace the oil seals.
    • Make sure that the opening of the snap rings are facing towards the bottom of the drive unit.
    • Carefully push the halfshaft into the drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
    • There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
  • Remove the suspension from "Jack" mode, and then set to "Standard" and allow the suspension to settle.

Perform the following:

  1. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  2. Unlock the vehicle gateway. See Gateway Unlock.
  3. In Toolbox 3, click the Actions tab, type "Calibrate-Steering-Column" into the search field, click PROC_EPAS_X_CALIBRATIONSearch for routine in ToolboxBosch EPAS Calibration, click Run, and allow the routine to complete.
  4. In Toolbox 3, click the Actions tab, type "ESP-CONFIG" into the search field, click PROC_ESP_X_ESP-CONFIGSearch for routine in ToolboxESP ConfigurationChassis / Brakes - ESP Config, click Run, and allow the routine to complete.
  5. Transfer the vehicle to a 4 post lift. See Raise Vehicle - 4 Post Lift.
  6. Perform a Lock To Lock-Angle test. See Lock To Lock-Angle Test.
  7. Fully torque all suspension components at ride height.
  8. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  9. Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.