01/04/2024 13:57:09

Bushing - Rear Drive Unit - Rear (3DU) (Remove and Replace)

Correction code 40012602 3.78 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT 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. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2024-01-11: Updated torque figure for the bolt that attaches the ground strap to the RDU from 6 Nm to 10 Nm.
  • 2023-10-25: Updated torque figure for rear upper fore link to knuckle from 76 Nm to 84 Nm.
  • 2023-08-23: Updated EPB Service Mode reference.
  • 2023-06-09: Added shear plate small bolts torque figure for Structural Pack vehicles.
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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
  1. Open all four doors
  2. Lower LH front window
  3. Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
  4. Move LH front seat forward
  5. Move RH front seat forward
  6. Remove 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Lift front edge of seat cushion upward to release foam from frame
  7. Open hood
  8. Remove rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  9. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off
  10. Disconnect 12V negative terminal and first responders loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
  11. Remove all items from pockets and ensure not wearing metal items
  12. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
  13. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  14. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
  15. Remove the ancillary bay probe lid cover from the ancillary bay cover
  16. Verify no high voltage
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  17. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
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    Note
    Confirm no visual damage present, Replace gasket if damage is found
  18. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
  19. Remove HV insulating gloves
  20. Remove LH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  21. Remove RH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  22. Loosen RH rear wheel
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    Note
    5x nuts, 21mm, 175 Nm
  23. Loosen LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  24. Raise vehicle partially and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to a comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  25. Remove LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  26. Remove RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  27. Remove RH rear brake caliper from knuckle and hang from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E18, 83 Nm, Discard bolts after removal
  28. Remove LH rear brake caliper from LH rear knuckle and hang from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E18, 83 Nm, Discard bolts after removal
  29. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  30. Remove mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm
  31. Remove bolts securing rear diffuser to body
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    Note
    9x bolts, 10mm, 4 Nm
  32. Remove clips securing rear diffuser to body and remove from vehicle
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    Note
    6x push clips
  33. Remove LH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  34. Remove RH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  35. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  36. Install spring compressor onto LH rear coil spring
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    Note
    Reference photos for clarification
  37. Unbolt LH strut from body at top mount
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    Note
    2x bolts, 15mm, 41 Nm
  38. Install spring compressor onto RH rear coil spring
  39. Unbolt RH strut from body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm
  40. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  41. Disconnect RH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  42. Remove RH side 12V subframe harness clip from body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  43. Disconnect LH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  44. Remove LH side 12V subframe harness clip from body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  45. Remove nut securing RDU ground strap to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  46. Remove nut securing LH rear stabilizer bar end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
  47. Remove stabilizer bar from LH rear end link
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
  48. Remove nut securing RH rear stabilizer bar end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
  49. Remove stabilizer bar from RH rear end link
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
  50. Position support stand to support front portion of rear subframe
  51. Remove bolts securing stabilizer bar to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, 11mm, 30 Nm, Discard after removal
  52. Lower support stand and remove stabilizer bar from vehicle
  53. Remove support stand from under vehicle
  54. Release clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  55. Release LH side hose clip from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  56. Release RH side hose clips from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  57. Release clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  58. Remove lower bolts securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm
  59. Remove upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  60. Remove upper bolts securing rear battery enclosure skid plate from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  61. Remove rear battery enclosure skid plate from HV battery pack
  62. Position coolant drain container underneath LH rear of HV battery
  63. Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs
  64. Position coolant drain container underneath LH RDU area
  65. Disconnect RDU inverter inlet tube from fluid coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Plug the hose end and the fluid coupling
  66. Position coolant drain underneath RH rear of HV battery
  67. Disconnect coolant outlet hose to rear PT return hose and plug hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary
  68. Remove coolant drain container from underneath vehicle
  69. Remove nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  70. Disconnect RDU HV cable from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
  71. Place subframe lifting tool into position underneath rear subframe
  72. Connect air supply to subframe lifting tool
  73. Raise subframe lifting tool to support rear subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    3x straps, Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure, Lower the vehicle if necessary, Recommend assistance
  74. Remove smaller fasteners for LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
  75. Remove large bolt securing LH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard after removal
  76. Remove smaller fasteners for RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
  77. Remove large bolt securing RH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard after removal
  78. Remove LH rear bolt securing subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Discard after removal
  79. Remove RH rear bolt securing subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Discard after removal
  80. Lower subframe lifting tool to remove subframe from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage components while lowering subframe
  81. Disconnect air supply from subframe lifting tool
  82. Move the subframe lifting tool and subframe away from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise vehicle if necessary
  83. Remove coolant inlet hose clip from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  84. Remove coolant inlet hose from subframe
  85. Remove bolt securing RDU HV cable bracket to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  86. Disconnect RDU HV cable from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Red locking tab
  87. Remove RDU HV cable from subframe
  88. Perform RDU diode test
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify RDU HV cable is disconnected from HV battery. Use a multimeter in diode mode, with the positive DMM probe to B- of the inverter and the negative probe to B+. Pin #1 on HV cables is B- and Pin #2 is B+. MOSFET acceptable diode reading:1.0 - 2.0 V. IGBT acceptable diode reading 0.45 - 2 V (if you get OL or > 2V for a reading you most likely have the probes installed the wrong way around)
  89. Remove ground strap harness from RDU assembly
  90. Remove LH rear wheel speed sensor from LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  91. Remove grommet securing LH rear wheel speed harness to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  92. Remove nut and bolt securing LH rear upper aft link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm
  93. Remove nut and bolt securing LH rear upper fore link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm
  94. Remove nut and bolt securing LH rear toe link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm
  95. Disconnect RDU 12V connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  96. Remove RDU 12V harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  97. Disconnect resolver connector from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x clips
  98. Disconnect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
  99. Remove RH rear wheel speed sensor from RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  100. Remove grommet securing RH rear wheel speed sensor to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  101. Remove nut and bolt securing RH rear upper aft link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm
  102. Remove nut and bolt securing RH rear upper fore link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm
  103. Remove nut and bolt securing RH rear toe link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm
  104. Release LH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
  105. Remove LH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Install axle seal plug
  106. Release RH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing
  107. Remove RH halfshaft from rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Install axle seal plug
  108. Position drive unit stand underneath gantry
  109. Attach drive unit sling tool to drive unit
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    Note
    3x hooks
  110. Secure drive unit sling to gantry
  111. Raise sling so there is slight tension on the cables
  112. Remove LH bolt securing drive unit to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm
  113. Remove RH bolt securing drive unit to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm
  114. Remove bolt securing rear of drive unit to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm
  115. Raise sling to lift drive unit out of subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Carefully guide halfshafts away from FDU while lifting
  116. Move subframe and lifting tool from underneath drive unit
  117. Position empty drive unit crate below drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Use pallet if no empty crate available
  118. Lower drive unit into drive unit crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Use pallet if no empty crate available
  119. Lower sling to release tension on the cables
  120. Remove drive unit sling from gantry
  121. Remove drive unit sling tool from drive unit
  122. Attach RDU engine stand adapter to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 15mm, 3x nuts, 15mm, Hand tight, Recommend assistance
  123. Attach gantry hook to RDU adapter
  124. Using gantry, lift RDU assembly for installation onto engine stand
  125. Move engine stand into position
  126. Install RDU adapter to engine stand
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 18mm, 4x nuts 18mm
  127. Install bushing removal tool on gearcase bushing
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 22mm, Use cups "C", "A", and "G" to drive bushing out, Always drive on the bearing side and hold the opposite
  128. Press gearcase bushing out from casting
  129. Separate bushing tool and remove gearcase bushing
  130. Setup tool to press in new gearcase bushing
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 22mm, Use cups "D" and "E" to install bushing, Always drive on the bearing side and hold the opposite, Ensure the keyway is up and the lug on the bushing is in the center of the "D" cup opening
  131. Press in new gearcase bushing
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    Note
    Apply spray lubricant to the bushing exterior before install
  132. Separate bushing tool and remove from drive unit
  133. Using the gantry hook, support the RDU engine stand adapter, applying tension
  134. Remove the bolts securing RDU engine stand adapter to engine stand and move engine stand away
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 18mm, 4x nuts, 18mm
  135. Lower RDU and engine stand adapter onto crate
  136. Remove gantry hook from RDU adapter and move aside
  137. Remove RDU engine stand adapter from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 15mm, 3x nuts, 15mm
  138. Attach drive unit sling tool to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    3x hooks
  139. Secure drive unit sling to gantry
  140. Raise drive unit out of drive unit crate
  141. Move subframe and lifting tool underneath drive unit
  142. Lower sling to install rear drive unit into subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Carefully guide halfshafts away from FDU while lowering
  143. Install rear bolt securing drive unit to subframe, hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm, Torque at a later step
  144. Install RH bolt securing drive unit to subframe, hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm, Torque at a later step
  145. Lower sling to release tension on the cables
  146. Remove drive unit sling from gantry
  147. Remove drive unit sling tool from drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    3x hooks
  148. Torque motor mount bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 18mm, 80 Nm
  149. Install LH halfshaft to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
  150. Install RH halfshaft to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove axle seal plug if necessary, Caution not to damage the axle seal during installation, Recommend assistance
  151. Secure clips holding coolant outlet hose to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  152. Secure coolant outlet hose to drive unit cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  153. Secure inverter to cooler hose to cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  154. Secure clips holding inverter to coolant hose to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  155. Secure inverter to cooler hose to inverter
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  156. Connect resolver connector to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x clips, Engage locking tab
  157. Connect oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  158. Install RH rear toe link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
  159. Install RH rear upper fore link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm, Recommend assistance, Torque at later step
  160. Install RH upper aft link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm, Recommend assistance
  161. Loosely install RH rear lower fore link to RH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 18mm, 76 Nm, Torque at later step
  162. Install grommet securing RH wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  163. Install bolt securing RH wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  164. Install RDU 12V harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  165. Install RDU 12V connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  166. Install the bolt that attaches the ground strap harness to the RDU assembly .
    10 Nm (7.4 lbs-ft)
  167. Install LH rear toe link to knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step
  168. Install the nut and bolt that attach the LH rear upper fore link to the knuckle.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 84 Nm, Torque at later step
  169. Install LH rear upper aft link to LH rear knuckle and hand tighten nut and bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 21mm, 134 Nm
  170. Loosely install LH rear lower fore link to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 1x nut, 18mm, 76 Nm, Torque at later step
  171. Install grommet securing LH rear wheel speed sensor harness to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  172. Install LH rear wheel speed sensor to LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 10mm, 5 Nm
  173. Install RDU HV cable into position on the rear subframe
  174. Connect RDU HV cable to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Install HV connector lever lock to RDU HV cable connector, Align connector to RDU then remove HV connector lever lock before fully latching connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position
  175. Install bolt securing RDU HV cable bracket to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  176. Install coolant inlet hose into subframe
  177. Remove hose plugs and connect coolant inlet hose to rear drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
  178. Install coolant inlet hose clip to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  179. Position subframe lifting tool and subframe under vehicle
  180. Connect air supply to subframe lifting tool
  181. Raise drive unit and subframe into position
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to not damage components while raising subframe
  182. Install RH rear bolt securing rear subframe to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
  183. Install LH rear bolt securing rear subframe to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
  184. Install bolt and shear plate to LH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
  185. Install bolts securing LH rear shear plate to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
  186. Install bolt and shear plate to RH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
  187. Install bolts securing RH shear plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
  188. Torque bolts securing shear plates to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
  189. Torque bolt securing subframe and LH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm
  190. Torque bolt securing subframe and RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm
  191. Torque bolt securing RH rear of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
  192. Torque bolt securing LH rear of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
  193. Install clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  194. Install clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  195. Lower rear subframe lifting tool from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify yellow safety straps are removed from subframe
  196. Disconnect air supply from subframe lifting tool
  197. Remove subframe lifting tool from underneath vehicle
  198. Connect RDU HV cable to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
  199. Install nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  200. Position coolant drain underneath RH rear of HV battery
  201. Remove hose plugs and connect coolant outlet hose to rear PT return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary
  202. Position coolant drain container underneath LH rear of HV battery
  203. Remove plugs and connect RDU inverter inlet hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  204. Remove coolant drain container from underneath vehicle
  205. Position rear battery enclosure skid plate to HV battery for installation
  206. Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, Torque at later step
  207. Install upper nut securing rear battery enclosure skid plate hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Torque at later step
  208. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  209. Torque bolts securing HV battery and rear skid plate to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  210. Torque upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  211. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  212. Install RH side hose clips to rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  213. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  214. Place stabilizer bar into position for installation and raise stand to support stabilizer bar
  215. Install bolts securing stabilizer bar to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, 11mm, 30 Nm, Install new patch bolts
  216. Position LH rear end link into stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
  217. Install nut securing LH rear end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
  218. Position RH rear end link into stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
  219. Install nut securing RH rear end link to stabilizer bar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
  220. Remove support stand from under vehicle
  221. Install the RDU ground strap to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  222. Install LH side 12V subframe harness clip to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  223. Connect LH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  224. Install RH side 12V subframe harness clip to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  225. Connect RH side 12V subframe harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  226. Install rear diffuser to rear fascia assembly and secure clips to body
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips
  227. Apply Loctite 222 onto rear diffuser bolts and install bolts securing rear diffuser to body
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 4 Nm
  228. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  229. Install bolts securing RH damper to body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm
  230. Install RH rear brake caliper onto knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
  231. Remove bolt securing RH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  232. Install hub jack adapter onto RH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  233. Position and raise support stand to simulate RH rear suspension at ride height
  234. Use rear ride height torque gauge to verify RH suspension is set to ride height specification
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to slightly adjust stand or compression tool
  235. Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height
    Informational PurposesAn informational icon, calling your attention
    Note
    Distance should be 427 mm
  236. Torque bolt securing RH rear toe link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  237. Torque the bolt that attaches the RH rear upper fore link to the knuckle.
    84 Nm (61.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 84 Nm, Mark with paint pen
  238. Torque bolt securing RH rear lower fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  239. Torque bolt securing RH rear upper aft link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 134 Nm, Mark with paint pen
  240. Remove support stand from underneath RH suspension
  241. Remove hub jack adapter from RH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  242. Install bolt securing RH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  243. Remove spring compressor from RH rear coil spring
  244. Install bolts securing LH damper to body at top mount
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 41 Nm, Apply pressure at top of damper to push down and clear wheel liner
  245. Install LH rear brake caliper onto LH rear knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
  246. Remove bolt securing LH rotor to hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  247. Install hub jack adapter onto LH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  248. Position and raise support stand to simulate LH rear suspension at ride height
  249. Use rear ride height torque gauge to verify LH suspension is set to ride height specification
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to slightly adjust stand or spring compressor tool
  250. Measure from bottom of quarter panel to center of axle as a secondary check to make sure LH suspension is set to ride height
    Informational PurposesAn informational icon, calling your attention
    Note
    Distance should be 427 mm
  251. Torque bolt securing LH rear toe link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  252. Torque the bolt that attaches the LH rear upper fore link to the knuckle.
    84 Nm (61.9 lbs-ft)
  253. Torque bolt securing LH rear lower fore link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 76 Nm, Mark with paint pen
  254. Torque bolt securing LH rear upper aft link to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 134 Nm, Mark with paint pen
  255. Remove support stand from underneath LH rear suspension
  256. Remove hub jack adapter from LH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  257. Install bolt securing LH rear rotor to LH rear hub
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  258. Remove spring compressor from LH rear coil spring
  259. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  260. Install LH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  261. Install RH rear suspension cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 2x tabs
  262. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 5 Nm
  263. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  264. Install LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  265. Install RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  266. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  267. Torque LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  268. Torque RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  269. Install RH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  270. Install LH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  271. Remove coolant bottle cap
  272. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  273. Connect first responder loop and 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
  274. Install 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
  275. Move RH front seat to original position
  276. Move LH front seat to original position
  277. Press and hold park button to release EPB service mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove wheel chocks if necessary
  278. Connect to vehicle using Toolbox 3.0
  279. Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
  280. Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
  281. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  282. Install coolant bottle cap
  283. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  284. Close hood
  285. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  286. Raise all four windows
  287. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If 12V is powered up, Unlatch rear doors before closing
  288. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  289. Check tire pressures
    Informational PurposesAn informational icon, calling your attention
    Note
    4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar
  290. Verify the alignment slip/turn plates are locked
  291. Drive vehicle onto alignment rack
  292. Pull vehicle forward and stop ~ 0.5 ft before turn plates to allow for rolling compensation
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift to park
  293. Shift to park
  294. Install wheel chocks
    Informational PurposesAn informational icon, calling your attention
    Note
    Place chocks on both sides of the driver's side rear tire
  295. Latch the driver seat belt to buckle
  296. Latch LH front door and place vehicle into neutral
    Informational PurposesAn informational icon, calling your attention
    Note
    Careful not to slam the door while latch is engaged
  297. Raise alignment rack partially and lower to lock position
  298. Install alignment heads onto wheels
    Informational PurposesAn informational icon, calling your attention
    Note
    4x alignment heads
  299. Enter vehicle information to alignment machine
  300. Perform rolling compensation
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the wheel chocks from the LH rear tire and push the back of the tire to roll vehicle forward. Reinstall wheel chocks once vehicle is in position
  301. Unlock alignment slip/turn plates
  302. Verify chassis height measurement tool is calibrated
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust if necessary, Measure height of tool and adjust reading to match
  303. Perform ride height measurement
    Informational PurposesAn informational icon, calling your attention
    Note
    Measure the ride height 75mm inward of the HV battery ski hole at each corner, If using ballast bags, move the front seats as necessary to achieve ride height spec, See Service Manual for ride height specifications
  304. Apply brake pedal depressor
  305. Perform caster sweep and install steering wheel holder and level tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If camber and caster are out of specification, perform necessary camber and caster adjustment
  306. Verify alignment reading is within specification and print vehicle summary
  307. Remove alignment heads from wheels
    Informational PurposesAn informational icon, calling your attention
    Note
    4x alignment heads
  308. Remove brake pedal depressor
  309. Lock alignment slip/turn plates
  310. Lower the alignment rack to ground
  311. Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
  312. Unlatch LH front seat belt
  313. Remove wheel chocks
  314. Remove vehicle from alignment rack
  315. Perform test drive
    Informational PurposesAn informational icon, calling your attention
    Note
    Per current FRT (00040100) 0.3 hrs, If alignment was adjusted verify tracking, If DAS components were adjusted verify operation, If brakes were serviced perform burnishing