2026-07-10

Rear Drive Unit - 3DU - High Current (Remove and Replace)

Correction code 4001020602 4.14 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.

  • 2026-07-10: Adjusted the step sequence of torquing the rear damper mounting bolt; added two alternative methods for setting the rear suspension to ride height.
  • 2026-06-04: Updated steps for LV maintainer connection.

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2-Post Lift.
  2. Open all four doors and lower all four windows.
  3. Move both front seats forward.
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the seat back if needed to avoid contacting headliner.
  4. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox (Connect and Disconnect).
  5. On the touchscreen, tap High Voltage System > Procedures > Rear Drive Unit Replacement.
  6. Select Start Coolant Fill/Drain, click Run, then allow the routine to complete.
  7. While holding the brake pedal, select Release / Re-Engage Emergency Parking Brake, select BOTH in the EPB Selection dropping list, and select START in the Action Selection dropping list, then click Run and allow the routine to complete
  8. Disconnect the laptop with Toolbox from the vehicle.
  9. Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  10. Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  11. Remove the LH and RH rear suspension aero covers. See Rear Suspension Cover - LH (Remove and Replace).
  12. Remove the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  13. Remove the nut that attaches the RDU ground strap to the body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 1/4in Dr. 12pt. Deep x 10mm
  14. Remove the rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
  15. Release the locking tab, then disconnect the RH subframe harness connector.
  16. Release the RH subframe harness clip from body.
  17. Remove and discard the bolts (x2) that attach the LH rear caliper to the LH rear knuckle, remove the caliper from the knuckle, and allow the caliper to hang from an S-hook.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E18 Torx Low Profile Socket
  18. Remove and discard the bolts (x2) that attach the RH rear caliper to the RH rear knuckle, remove the caliper from the knuckle, and allow the caliper to hang from an S-hook.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E18 Torx Low Profile Socket
  19. Remove the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  20. Install the spring compressor onto the LH and RH rear coil springs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Compressor plates are installed one way. Top plate has notches, while lower plate does not. Reference photos for clarification.
  21. Remove the bolt and nut that attach the LH rear damper to the LH rear lower aft link.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21 mm socket
  22. Repeat step 21 for the RH side.
  23. Remove the RDU inlet hose. See Hoses - Tube (PT) - RDU Inverter Inlet - 3DU (Remove and Replace).
  24. Remove the RDU HV harness. See High Voltage Harness Rear Drive Unit (3DU) (Remove and Replace).
  25. Place the subframe lifting tool into position underneath the rear subframe.
  26. Connect the air supply to the subframe lifting tool.
  27. With assistance, raise the subframe lifting tool to support the rear subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    • Attach the metal hooks at the end of the straps to rings on the subframe lifting tool.
    • Lower the vehicle if necessary.
  28. Remove the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  29. Remove the rear subframe brace. See Brace - Rear Subframe (Remove and Replace).
  30. With assistance, lower the subframe lifting tool to remove the subframe and rear drive unit assembly from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage the components while lowering the subframe.
  31. Disconnect the air supply from the subframe lifting tool.
  32. With assistance, position the subframe lifting tool and subframe away from the vehicle.
  33. Disconnect the rear drive unit logic connector, and move the connector aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Prevent coolant ingress into the connector.
  34. Release the rear drive unit logic connector clip.
  35. Release the clips (x2) and disconnect the resolver connector from the rear drive unit.
  36. Pull the red tab to disengage the lock, and then pull again to release and disconnect the oil pump connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not push down on the red tab.
  37. Remove the bolt that attaches the ground strap harness to the RDU.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 1/4in Dr. 6pt. Std. x 10mm
  38. Place a fluid catcher under the subframe and fixture assembly to collect all coolant spillage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a foldable funnel if needed.
  39. Remove the RDU inverter to oil cooler hose. See Tube- Rear Drive Inverter to Oil Cooler - 3DU (Remove and Replace).
  40. Remove the RDU outlet hose. See Hoses - Hose (PT), RDU Outlet. (Remove and Install).
  41. Remove the grommet that attaches the LH rear ABS wheel speed sensor cable to the knuckle.
  42. Remove the bolt that attaches the LH front ABS wheel speed sensor to the knuckle, and then set the sensor aside.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T30 socket
    • Cordless Ratchet/Impact Driver
    • Flex head ratchet/flex head torque wrench
    • 4 in extension
  43. Remove the bolt and nut that attach the LH rear upper aft link to the LH rear knuckle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21 mm socket
    • Flex head ratchet/flex head torque wrench
  44. Remove the bolt and nut that attach the LH rear upper fore link to the knuckle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 18 mm socket
    • 3 in extension
    • Cordless Ratchet/Impact Driver
    • Flex head ratchet/flex head torque wrench
  45. Remove the bolt and nut that attach the LH rear toe link to knuckle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless 3/8in Dr Impact
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  46. Loosen the bolt and nut that attach the LH rear lower fore link to knuckle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the fasteners.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless 3/8in Dr Impact
    • 18 mm deep socket
    • 3 in extension
    • Flex head ratchet/flex head torque wrench
  47. Separate the LH halfshaft from the RDU using the cable removal kit.
    1. Wrap the cable around the inner joint and secure it hand-tight with the U-bolt.
    2. Attach the slide hammer to the cable eyelets and pull to release the LH halfshaft from the RDU.
    3. Remove the cable once complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take care not to damage the halfshaft boots and oil seals.
  48. Repeat from step 41 to step 47 to separate the RH halfshaft from the rear drive unit.
  49. Position the rear subframe and rear drive unit assembly under a gantry.
  50. Attach the drive unit sling tool to the rear drive unit using the hooks (x3).
  51. Secure the drive unit sling to the gantry.
  52. Raise the sling until the cables have slight tension to ensure a secure connection.
  53. Remove the bolts (x3) that attach the LH, RH, and rear of the drive unit to the subframe.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 3/8in Dr. 6pt. Std. x 18mm
  54. Carefully raise the sling to lift the drive unit out of subframe. As the rear drive unit is lifted, maneuver the halfshafts out of the way.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful not to damage the heat exchanger and coolant hoses.
  55. Position an empty drive unit crate below the rear drive unit.
  56. Carefully lower the old RDU into the crate.
  57. Install the bolts (x3) that attach the RDU to the RDU crate.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 3/8in Dr. 6pt. Std. x 19mm
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise and lower RDU as needed to align the bolts. Use a prybar as required.
  58. Lower the sling to relieve tension on the cables.
  59. Remove the drive unit sling from the old RDU.
  60. Remove the drive unit sling from the gantry hook.
  61. Move the old RDU away and prepare for MRB.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark MRB as required.

Replace

  1. Position the new RDU and crate underneath the gantry.
  2. Release the protective covers (x10) from the new RDU and transfer them onto the old RDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Numbers of cover may vary.
  3. Secure the drive unit sling onto the new RDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Follow the instruction and layout on the tool.
    Informational PurposesAn informational icon, calling your attention
    Note
    Sling is color-coded.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the sling is fully and properly secured.
  4. Raise the gantry hook to put tension on the sling.
  5. Remove the bolts (x3) that attach the RDU to the crate.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 3/8in Dr. 6pt. Std. x 19mm
    Informational PurposesAn informational icon, calling your attention
    Note
    Numbers of bolt may vary.
  6. Lift the new RDU out of the shipping crate and position it over the rear subframe assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  7. Carefully lower the rear drive unit into the rear subframe. As the rear drive unit is lowered, maneuver the halfshafts into the drive unit for later installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful not to damage the heat exchanger and coolant hoses.
  8. Hand-tighten the LH, RH and rear bolts that attach the drive unit to subframe.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at a later step.
  9. Lower the sling to release the tension on the cables.
  10. Torque the LH, RH and rear bolts that attach the drive unit to subframe.
    80 Nm (59.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
    • 18 mm socket
  11. Remove the drive unit sling tool from the rear drive unit.
  12. Remove the drive unit sling tool from the gantry.
  13. Remove the rear subframe and rear drive unit assembly from under a gantry.
  14. With the help of an assistant, slightly rotate the LH halfshaft so as to align the splines of the halfshaft to those in the rear drive unit, lift up on the LH rear knuckle to help move the halfshaft into the drive unit, and then apply force to seat the halfshaft in the drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the two assemblies together if they are not aligned correctly. Lift up on the knuckle as needed.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the halfshaft binds, back the halfshaft out, rotate it slightly, and try again.
    Informational PurposesAn informational icon, calling your attention
    Note
    A snap is heard when the retaining clip seats onto the fully inserted halfshaft.
  15. Position the LH rear toe link onto the knuckle, and then install and hand-tighten the bolt and nut.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Recommend assistance when performing this step.
  16. Install the LH rear upper fore link to the knuckle and hand-tighten the nut and bolt.
  17. Position the LH rear upper aft link onto the knuckle, and then install and hand-tighten the bolt and nut.
  18. Install the grommet that attaches the LH rear ABS wheel speed sensor cable to the knuckle.
  19. Install the LH rear wheel speed sensor to the knuckle and then install the bolt that attaches the LH rear ABS wheel speed sensor to the knuckle.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T30 socket
    • Flex head ratchet/flex head torque wrench
    • 4 in extension
  20. Repeat from step 14 to step 19 to secure the RH halfshaft onto the rear drive unit.
  21. Engage the locking tab, then connect the oil pump connector.
  22. Secure the clips (x2) and connect the resolver connector to the rear drive unit.
  23. Secure the rear drive unit logic connector clip.
  24. Connect the rear drive unit logic connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Prevent coolant ingress into the connector.
  25. Install the bolt that attaches the ground strap harness to the RDU.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 1/4in Dr. 6pt. Std. x 10mm
  26. Install the RDU outlet hose. See Hoses - Hose (PT), RDU Outlet. (Remove and Install).
  27. Install the RDU inverter to oil cooler hose. See Tube- Rear Drive Inverter to Oil Cooler - 3DU (Remove and Replace).
  28. Position the subframe and rear drive unit assembly underneath the vehicle.
  29. Connect the air supply to the subframe lifting tool.
  30. With assistance, raise the rear drive unit and subframe assembly into position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage the components while raising the subframe.
  31. Install the rear subframe brace. See Brace - Rear Subframe (Remove and Replace).
  32. Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  33. Lower the rear subframe lifting tool from the vehicle, then remove the yellow safety straps (x3) from the subframe.
  34. Disconnect the air supply from the subframe lifting tool.
  35. Remove the subframe lifting tool from underneath the vehicle.
  36. Position the support stand underneath the LH rear lower aft link.
  37. Hand-tighten the bolt and nut that attach the LH rear damper to the LH rear lower aft link.
  38. Remove the support stand from the LH rear suspension.
  39. Repeat from step 36 to step 38 for the RH side.
  40. Install the RDU HV harness. See High Voltage Harness Rear Drive Unit (3DU) (Remove and Replace).
  41. Install the RDU inlet hose. See Hoses - Tube (PT) - RDU Inverter Inlet - 3DU (Remove and Replace).
  42. Install the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  43. Install the rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear (Remove and Replace).
  44. Install the RH side subframe harness clip to the body.
  45. Engage the locking tab, then connect the RH side subframe harness connector.
  46. Install the bolt that attaches the RDU ground strap to the body.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 1/4in Dr. 12pt. Deep x 10mm
  47. Remove the S-hook, then install new bolts (x2) that attach the LH rear caliper to the LH rear knuckle.
    83 Nm (61.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E18 Torx Low Profile Socket
  48. Remove the S-hook, then install new bolts (x2) that attach the RH rear caliper to the RH rear knuckle.
    83 Nm (61.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E18 Torx Low Profile Socket
  49. Remove the bolt that attaches the LH rear brake rotor to the hub.
    Informational PurposesAn informational icon, calling your attention
    Note
    The fastener type may vary on newer vehicles.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SOCKET, 1/4" DR., DEEP, MAGNETIC, 10MM
    • SKT, 1/4" DR, HEX BIT, T30 TORX
  50. Install the hub jack adapter onto the LH rear hub and hand-tighten the lug nuts (x5).
  51. Use an underhoist stand to support the hub jack adapter.
  52. Choose one of the following methods to set the rear suspension to ride height:
    1. Direct Measurement: Measure the distance between the bottom of the quarter panel and the center of the rear axle to make sure that the rear suspension is set to ride height. The distance should measure 428 mm.
    2. Use the Ride Height Measurement Tool (if equipped):
      1. Install the ride height measurement tool onto the LH rear hub jack adapter.
      2. Adjust the level to center the bubble within the reference marks, slide the movable cover to align the "MY REAR" marking, ensure the arrow on the cover matches the arrow on the scale, then securely tighten the sliding cover bolt.
      3. Adjust the under-hoist stand height, and use the sliding cover to extend the rod until it contacts the fender garnish.
  53. Tighten the bolt and nut that attach the LH rear damper to the LH rear lower aft link, and then mark the bolt and nut with a paint pen.
    115 Nm (84.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21 mm socket
  54. Tighten the bolt and nut that attach the LH rear upper aft link to the knuckle, and then mark the bolt and nut with a paint pen.
    134 Nm (98.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21 mm socket
    • Flex head ratchet/flex head torque wrench
  55. Tighten the bolt and nut that attach the LH rear upper fore link to the knuckle, and then mark the bolt and nut with a paint pen.
    84 Nm (61.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 18 mm socket
    • 3 in extension
    • Cordless Ratchet/Impact Driver
    • Flex head ratchet/flex head torque wrench
  56. Tighten the bolt and nut that attach the LH rear toe link to the LH rear suspension knuckle. Mark the bolt with a paint pen.
    76 Nm (56.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless 3/8in Dr Impact
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  57. Tighten the bolt and nut that attach the LH rear lower fore link to the LH rear knuckle. Mark the bolt with a paint pen.
    76 Nm (56.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless 3/8in Dr Impact
    • 18 mm deep socket
    • 3 in extension
    • Flex head ratchet/flex head torque wrench
  58. Remove the underhoist stand from underneath the LH rear suspension.
  59. Remove the lug nuts (x5) that attach the hub jack adapter, and then remove the hub jack adapter from the vehicle.
  60. Install the bolt that attaches the LH rear brake rotor to the hub.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The fastener type may vary on newer vehicles.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SOCKET, 1/4" DR., DEEP, MAGNETIC, 10MM
    • SKT, 1/4" DR, HEX BIT, T30 TORX
  61. Repeat from step 49 to step 60 for the RH side.
  62. Remove the spring compressor from the LH and RH rear coil springs.
  63. Install the LH and RH rear suspension covers. See Rear Suspension Cover - LH (Remove and Replace).
  64. Install the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  65. Install the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  66. Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  67. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  68. Connect the LV power. See LV Power (Disconnect and Connect) (Modify).
  69. Connect an LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  70. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox (Connect and Disconnect).
  71. On the touchscreen, tap High Voltage > Procedures > Rear Drive Unit Replacement.
  72. Select Stop Coolant Fill/Drain, then click Run and allow the routine to complete.
  73. Select CAN Redeploy, then Run and allow the routine to complete.
  74. Disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  75. Select Coolant Air Purge, then click Run and allow the routine to complete.
  76. Select Thermal System Test, then click Run and allow the routine to complete.
  77. On the touchscreen, tap Chassis > Brakes > EPB Service Mode, select BOTH in the EPB Selection dropping list, and select STOP in the Action Selection dropping list, then click Run and allow the routine to complete
  78. Disconnect the laptop with Toolbox from the vehicle.
  79. Exit Service Mode. See Service Mode.
  80. Disconnect an LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  81. Install the HEPA filter or cowl assembly. See HEPA Filter Assembly (Remove and Replace) or Cowl Assembly - non-HEPA (Model Y Standard) (Remove and Install).
  82. Move both LH and RH front seats to their original positions.
  83. Raise all four window and close all four doors.
  84. Remove the vehicle from the lift.
  85. 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.