2026-04-07

Rear Drive Inverter (3DU) (Remove and Replace)

Correction code 4020040002 FRT 2.88 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.

Remove

  1. Inspect the vehicle for abnormal tire wear that might indicate the need for a wheel alignment. Note any findings.
  2. Place the vehicle on the 2-post lift.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Ensure the vehicle is not charging.
  3. Open all doors and lower all windows.
  4. Move both front seats forward.
  5. Perform Before-Inverter-Replacement routines.
    1. Locally connect a laptop with Toolbox to the vehicle. See Toolbox (Connect and Disconnect).
    2. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap High Voltage > Procedures > Rear Drive Inverter Replacement > Store Bootloader Data > Run, and allow the routine to complete.
    3. Tap Store Application Data > Run, and allow the routine to complete.
    4. Tap Start Fluid Fill/Drain > Run, and allow the routine to complete.
    5. Disconnect the laptop.
  6. Remove the rear drive inverter and place it on an ESD mat. See Rear Drive Inverter (3DU) (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    No need to separate the gasket from the inverter as this is a Remove and Replace procedure. Replace it together with the inverter. Remove the ESD wrist strap from the inverter housing after removing the inverter.
  7. If the pyrotechnic fuse of the drive unit inverter has not been actuated, dispose of the drive unit inverter as hazardous material. If the pyrotechnic fuse has been actuated, follow the normal regulations for waste disposal.
    Informational PurposesAn informational icon, calling your attention
    Note
    If Autodiag falsely indicated that the pyrotechnic fuse was actuated, but visual check confirms that it was not activated, list the serial number of the drive unit inverter in Autodiag using 'Report an Issue'.

Install

  1. Prepare the new drive inverter.
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    Note
    Save the packaging to MRB old drive inverter. Remove any red protective covers.
  2. Secure the ESD strap to the new inverter housing.
  3. Install the new inverter to the vehicle. See Rear Drive Inverter (3DU) (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    After installing the RDU phase out cover and the 3-phase access label, back to current procedure.
  4. Put on the ESD wrist strap, package the old inverter and prepare for MRB. Label properly for return or disposal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure any protective red caps. Return or dispose of packaging through proper channels. Label the part as MRB.
  5. Continue installing the new inverter. See Rear Drive Inverter (3DU) (Remove and Install).
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    Note
    After installing both rear wheels, return to current procedure and move on.
  6. Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  7. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  8. Connect the first responder loop and leave the LV battery disconnected.
  9. Connect an LV maintainer. See LV Maintainer (Maintenance).
  10. Perform After-Inverter-Replacement and After-Successful-Redeploy routines.
    1. Locally connect a laptop with Toolbox to the vehicle. See Toolbox (Connect and Disconnect).
    2. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap High Voltage > Procedures > Rear Drive Inverter Replacement > Stop Fluid Fill/Drain > Run, and allow the routine to complete.
    3. Tap Restore Bootloader Data > Run, and allow the routine to complete.
    4. Tap CAN Redeploy > Run, and allow the routine to complete.
    5. Once the reinstallation is complete, check that the release notes appear on the touchscreen, indicating a successful reinstallation.
    6. Tap Restore Application Data > Run, and allow the routine to complete.
    7. Tap Immobilizer/ODO Pairing > Run, and allow the routine to complete.
    8. Tap Coolant Air Purge > Run, and allow the routine to complete.
  11. Disconnect the LV maintainer and connect the LV battery.
  12. Inspect the coolant level and top off as necessary.
  13. Install the coolant bottle cap.
  14. Install the HEPA filter assembly. See HEPA Filter Assembly (Remove and Replace).
  15. Move both front seats to original position.
  16. After the Coolant Air Purge routine is completed, continue to perform the After-Successful-Redeploy routines.
    1. Tap Thermal System Test > Run, and allow the routine to complete.
    2. Place stanchions around the vehicle and set up safety perimeter.
    3. Raise the vehicle to a comfortable working height, and lower the lift onto locks.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION

      Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.

      Make sure that the doors are clear of surrounding objects.

    4. Press the brake pedal to turn on the drive rails.
    5. Tap Resolve Error Learn > Run, and allow the routine to complete.
    6. Disconnect the laptop.
    7. Press and hold Exit Service Mode to exit Service Mode Plus.
    8. Remove the safety stanchions and lower the vehicle.
  17. Raise all windows and close all doors.
  18. Remove the vehicle from the lift.
  19. 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.