Before continuing, move the
subframe fixture to the gantry.
Disconnect the motor encoder.
Release the wheel speed sensor harnesses from the grommets on the subframe.
On both sides of the subframe, release the bolt that secures the upper link to the knuckle (torque 140 Nm).
On both sides of the subframe, release the bolt that secures the toe link to the knuckle (torque 130 Nm).
Position the axle remover cable around the inner joint of the LH rear drive unit halfshaft, and then use a cable tie to hold the axle remover cable in position.
Figure 1. Axle removed from drive unit for demonstration purposes
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 drive unit.
Repeat the previous 2 steps to remove the RH rear drive unit halfshaft.
Attach the drive unit sling to
the gantry, and then install the bolts (x3) that attach the sling to the drive
unit.
Note
Secure the short bolt to the
motor section of the drive unit.
Loosen the nuts that secure the front and rear motor mounts to the subframe (torque 90 Nm).
Loosen the bolts (x3) that secure the motor to the side motor mount. (torque 22 Nm).
Tip: It might be helpful to only use the gantry bolt that secures to the motor. This allows the drive unit to be rotated to better align the bolt holes.
Tip: When removing the bolts that secure the front and rear motor mounts, it might be helpful to use a screwdriver or small prybar to pry against the subframe. This helps to align the bolt holes in the motor mounts with the subframe so that the bolts can be easily removed.
Remove the bolt that secures the front motor mount (torque 90 Nm).
Remove the bolt that secures the rear motor mount (torque 90 Nm).
CAUTION
While lifting the drive unit assembly in the next step, have an assistant brace a screwdriver or similar tool against the subframe and hold the stabilizer bar out of the way. Do not brace the tool against the motor mount.
Carefully lift the drive unit assembly, making sure to clear the rear of the subframe.
CAUTION
Do not damage the motor encoder plastic housing.
Installation
Installation procedure is the reverse of removal, except for the following:
CAUTION
When raising the
subframe and drive unit into the vehicle, avoid making contact with the Rapid
Splitter.
CAUTION
Replace all patchbolt(s).
CAUTION
Replace all nylon-insert
locknuts.
CAUTION
Ensure that the new halfshaft has a
snap-ring already installed. If it does not, then install a different halfshaft that
has a snap-ring already installed. Return any halfshafts without a snap-ring using
the MRB process. Do not remove or reuse snap-rings.
When installing the halfshaft(s) into the drive unit:
Make sure that the opening of the snap ring is facing towards the bottom of the drive unit.
Do not damage or displace the oil seal.
Verify that the halfshaft is fully seated:
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.
Pull on the inner halfshaft cup 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.
Ensure that the drive unit is
equipped with a bracket that correctly routes the HV cables. If necessary, install
a screw and bracket to correctly route the HV cables (torque 8 Nm).
Note
Components have been removed
in this graphic to aid clarity.
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 (refer to procedure).
If only the rear drive unit was
removed, bleed the cooling system (refer to procedure).
Air suspension only: Set the
suspension height to “Normal”.
CAUTION
Only fully tighten suspension nuts
and bolts when the vehicle is on a 4-post lift and the suspension is in the ride
height position.
Make sure to take note of the last step in the Subframe Assembly - Rear (Remove and Install) procedure: 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.
Tip: When removing the bolts that secure the front and rear motor mounts, it might be helpful to use a screwdriver or small prybar to pry against the subframe. This helps to align the bolt holes in the motor mounts with the subframe so that the bolts can be easily removed.
