17/08/2022 09:48:04
Drive Unit - Rear - Small (Remove and Install)
Correction Code 40016001
Special tools required for this procedure:
CAUTION
Use the specified
coolant only. In this manual, refer to Fluids.
Supplier | Part Number | Description |
Tesla | 1071308-00-B | Small Drive Unit Sling |
Tesla | 1046674-00-C | COVER, HV, INV, 3.0-150 |
Tesla | 1498673-00-A | KIT, CABLE AXLE REMOVER, MS/MX/M3 |
Tesla | 1031106-00-A | AST Fluid Pump |
Note
New small rear drive units are shipped
with 1046674-00-C.
Removal
- Remove the rear subframe. See Small RDU.
- Move the subframe fixture and transmission jack to the gantry area.
-
Place a coolant catcher under the
subframe fixture.
NoteThe 2 coolant hoses that are still attached to the small rear drive unit are removed as an assembly.
- Release the clip that attaches the coolant hoses to the rear subframe.
- Release the clip that attaches the low voltage harness to the coolant hoses.
- At the front of the small rear drive unit, remove the bolt that attaches the coolant hose bracket (torque 5.5 Nm).
-
Plug the holes for the HV
cables.
CAUTIONDo not allow coolant to enter the openings for the HV cables.
- Disconnect the 2 coolant hoses from the front LH side of the small rear drive unit.
- Disconnect the 2 coolant hoses from the RH side of the small rear drive unit.
- On each side of the rear subframe, release the 2 grommets that attach the wheel speed sensor harness.
- On each side of the rear subframe, remove the bolt that attaches the upper link to the knuckle (torque 140 Nm).
- On each side of the rear subframe, remove the bolt that attaches the toe link to the knuckle (torque 130 Nm).
-
Position the axle remover cable
around the inner joint of the LH small rear drive unit halfshaft, and then use a
cable tie to hold the axle remover cable in position.
- Hook the axle remover slide hammer on the 2 axle remover cable loops, and then use the slide hammer to remove the halfshaft from the small rear drive unit.
- Repeat the previous 2 steps to remove the RH small rear drive unit halfshaft.
- Remove and discard the cable tie that attaches the NVH pad to the small rear drive unit.
- Working from behind the small rear drive unit, release the hook-and-loop straps that attach the NVH pad.
- Working in front of the small rear drive unit, remove the clip that attaches the NVH pad to the LH side motor mount.
- Pull the NVH pad outboard to remove it.
- Remove the NVH pad from the LH side of the small rear drive unit:
- Remove the bolt that attaches the front of the small rear drive unit to the rear subframe (torque 90 Nm).
- Remove the bolt that attaches the rear of the small rear drive unit to the rear subframe (torque 90 Nm).
-
Remove the 3 bolts that attach
the LH side motor mount to the small rear drive unit (torque 22 Nm).
NoteThis causes the LH side of the small rear drive unit to drop slightly.
- Remove the bolt that attaches the LH side motor mount to the rear subframe (torque 90 Nm).
- Push the LH side motor mount outboard.
-
Attach the blue, red, and yellow
sling mounts of the sling tool to the small rear drive unit.
NoteThe black sling mount is not used in this procedure.
1 Red sling mount 2 Blue sling mount 3 Yellow sling mount NoteWhen securing the yellow sling mount, use the hoist ring with the sleeve spacer.1 Sleeve spacer - Secure the sling tool to the gantry.
- Lift the small rear drive unit out of the rear subframe.
- Set the small rear drive unit down onto a pallet, and then remove the sling tool from the gantry and from the small rear drive unit.
Installation
CAUTION
Replace all patchbolt(s).
CAUTION
Replace all nylon-insert
locknuts.
-
Attach the blue, red, and yellow
sling mounts of the sling tool to the replacement small rear drive unit.
1 Red sling mount 2 Blue sling mount 3 Yellow sling mount NoteWhen securing the yellow sling mount, use the hoist ring with the sleeve spacer.1 Sleeve spacer - Secure the sling tool to the gantry.
-
Lift the replacement small rear
drive unit out of the shipping crate and position it into the subframe.
NoteWhen lowering the small rear drive unit into the subframe, do not align the rear mount on the small rear drive unit with the mounting hole in the rear subframe. Instead, pull the rear mount beyond the rear subframe. This provides enough clearance for the front of the small rear drive unit to rotate into position as the rear subframe is lowered.
- Remove the sling tool from the gantry, and from the replacement small rear drive unit.
- Install the bolt that secures the front of the drive unit to the rear subframe (torque 90 Nm).
- Install the bolt that secures the rear of the drive unit to the rear subframe (torque 90 Nm).
- Install the LH side motor mount to the rear subframe, and then install the bolt that attaches the motor mount to the subframe (torque 90 Nm).
- Raise the LH side of the small rear drive unit, and then install the 3 bolts that secure the LH side motor mount to the small rear drive unit (torque 22 Nm).
-
Insert the fluid pump through the
axle seal and fill the drive unit with 2,250 ml of the recommended fluid. Refer to
Fluids.
NotePump fluid into the drive unit slowly.
- Position the NVH pad over the small rear drive unit.
- Fasten the clip that attaches the NVH pad to the LH side motor mount.
- Fasten the hook-and-loop straps that attach the NVH pad.
- Install a new cable tie to attach the NVH pad to the small rear drive unit.
- Align the LH halfshaft so that the opening in the snap ring is down, facing towards the bottom of the small rear drive unit.
-
Insert the LH halfshaft into the
small rear drive unit.
NoteDo not damage or displace the oil seal.
-
Carefully push the LH halfshaft
into the small rear drive unit until there is an audible "click" from the
halfshaft stub contacting the pinion shaft.
NoteThere will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
-
Pull on the LH inner halfshaft
cup to confirm that the LH halfshaft circlip is locked into place.
NoteIf the halfshaft detaches from the small rear drive unit, repeat from step 14 and then test that the halfshaft is fully seated.
- Repeat step 14 through 17 for the RH halfshaft.
- On each side of the rear subframe, install the bolt that attaches the toe link to the knuckle (torque 130 Nm).
- On each side of the rear subframe, install the bolt that attaches the upper link to the knuckle (torque 140 Nm).
- On each side of the rear subframe, fasten the 2 grommets that secure the wheel speed sensor harness.
- Install the 2 coolant hoses to the RH side of the small rear drive unit.
- Install the 2 coolant hoses to the front LH side of the small rear drive unit.
- Remove the plugs from the holes for the HV cables.
- At the front of the small rear drive unit, install the bolt that attaches the coolant hose bracket to the small rear drive unit (torque 5.5 Nm).
- Fasten the clip that attaches the low voltage harness to the coolant hoses.
- Fasten the clip that attaches the coolant hoses to the rear subframe.
- Remove the coolant catcher from under the subframe fixture.
- Return the subframe fixture and transmission jack to the work area.
- Carefully inspect the connector seals of the HV cables. If any are damaged, replace them.
-
Apply P-80 emulsion to the
connector seals of the HV cables.
CAUTIONDo not apply P-80 emulsion to the HV terminals.
-
Install the rear subframe. See
Small RDU.
CAUTIONOnly fully tighten the suspension bushing bolts when the vehicle is in ride height position.
- If both the front and rear drive units were removed at the same time, the vacuum refill tool must be used to refill the cooling system. See Cooling System - Vacuum Refill.
- If only the rear small rear drive unit was removed, bleed the cooling system. See Cooling System - Partial Refill and Bleed.
- Use the sling tool and gantry to lift the old small rear drive unit off the pallet and into the shipping crate.