01/04/2024 14:05:03

Subframe Assembly - Rear (Remove and Replace)

Correction code 30010202 4.56 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.

  • 2023-10-25: Updated torque figure for rear upper fore link to knuckle and subframe from 76 Nm to 84 Nm.
  • 2023-08-25: Updated EPB Service Mode reference.
  • 2023-06-15: Added shear plate small bolts torque figure for Structural Pack vehicles.
  • 1099645-00-B Fixture, Subframe, Model 3
  • 1130279-00-A Lifting Sling, Drive Unit, Model 3 (NA, APAC)
  • 1130481-00-A Adapter, Subframe, Body Shop, Model 3
  • 1096075-00-A Tool, Hub Puller, Hydraulic
  • 1498673-00-A KIT, CABLE AXLE REMOVER, MS/MX/M3
  • 1140311-00-A Lever Lock, HV Connector, Model 3

Torque Specifications

Table 1. Torque Specifications: Subframe Assembly - Rear (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the rear of the rear drive unit to the rear subframe
80 Nm (59.0 lbs-ft)
  • 18 mm socket
Reuse
Bolt that attaches the LH mount of the rear drive unit to the rear subframe
80 Nm (59.0 lbs-ft)
  • 18 mm socket
Reuse
Bolt that attaches the RH mount of the rear drive unit to the rear subframe
80 Nm (59.0 lbs-ft)
  • 18 mm socket
Reuse
Bolt and nut that attaches the RH rear upper aft link to the subframe
134 Nm (98.8 lbs-ft)
  • 21 mm socket
  • 21 mm combination wrench
 Reuse
Bolt and nut that attaches the RH rear upper fore link to the subframe
84 Nm (61.9 lbs-ft)
  • 18 mm socket
  • 18 mm combination wrench
  • flex head ratchet
 Reuse
Bolt and nut that attaches the RH rear toe link to the subframe
85 Nm (62.7 lbs-ft)
  • 18 mm deep socket
  • 18 mm combination wrench
  • flex head ratchet
 Reuse
Bolt and nut that attaches the RH rear lower fore link to the subframe
76 Nm (56.0 lbs-ft)
  • 18 mm socket
  • 18 mm combination wrench
  • flex head ratchet
 Reuse
Bolt that attaches the HV harness bracket to the inverter
6 Nm (4.4 lbs-ft)
  • 10 mm socket
Reuse
Smaller bolts that attach the LH and RH shear plates to the vehicle (non-Structural Pack vehicles)
35 Nm (25.8 lbs-ft)
Tip: Use of the following tool(s) is recommended:
  • 13 mm socket
  • 3 in extension
Reuse
Smaller bolts that attach the LH shear plate to the HV battery (Structural Pack vehicles)
62 Nm (45.7 lbs-ft)
  • 13 mm socket
  • 3 in extension
Large bolts that attach the LH and RH shear plates to the vehicle
130 Nm (95.9 lbs-ft)
  • 21 mm socket
  • 6 in extension
replace
Bolts that attach the LH and RH rear subframe to the body
165 Nm (121.7 lbs-ft)
  • 21 mm socket
  • 6 in extension
 replace
Nut that attaches the HV battery to rear drive unit harness bracket to the HV battery
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • 4 in extension
Reuse
Nut that attaches the rear drive unit ground strap to the body
10 Nm (7.4 lbs-ft)
  • 10 mm 12-point deep socket
Reuse
Bolts that attach the LH rear damper at the top mount
41 Nm (30.2 lbs-ft)
  • 15 mm socket
  • 3 in extension
Reuse
Bolts that attach the LH rear brake caliper bracket to the knuckle
83 Nm (61.2 lbs-ft)
  • External Torx E18
Replace
Bolt that attaches the rear LH ABS wheel speed sensor to the knuckle
5 Nm (3.7 lbs-ft)
  • 10 mm socket
  • 6 in extension
Reuse
Bolt that attaches the LH front rotor to the LH front hub
5 Nm (3.7 lbs-ft)
  • 10 mm socket
  • 2 in extension
  • Ratchet/torque wrench
Reuse
Bolt and nut that attach the LH rear upper aft link to the knuckle
134 Nm (98.8 lbs-ft)
  • 21 mm socket
  • 6 in extension
Reuse
Informational PurposesAn informational icon, calling your attention
Note
The bolt and nut will be tightened to specification during the Four Wheel Alignment (Check and Adjust) at the end of the Front Subframe Assembly (Remove and Install) procedure.
Bolt and nut that attach the LH rear upper fore link to the knuckle
84 Nm (61.9 lbs-ft)
  • 21 mm socket
  • 6 in extension
Reuse
Informational PurposesAn informational icon, calling your attention
Note
The bolt and nut will be tightened to specification during the Four Wheel Alignment (Check and Adjust) at the end of the Front Subframe Assembly (Remove and Install) procedure.
Bolt and nut that attach the RH rear upper fore link to the knuckle
84 Nm (61.9 lbs-ft)
  • 21 mm socket
  • 6 in extension
Reuse
Bolt and nut that attach the LH rear toe link to the knuckle
76 Nm (56.0 lbs-ft)
  • 18 mm socket
Reuse
Informational PurposesAn informational icon, calling your attention
Note
The bolt and nut will be tightened to specification during the Four Wheel Alignment (Check and Adjust) at the end of the Front Subframe Assembly (Remove and Install) procedure.
Bolt and nut that attaches the LH rear lower fore link to the knuckle
76 Nm (56.0 lbs-ft)
  • 18 mm socket
  • 18 mm ratcheting combination wrench
  • Flex head ratchet/flex head torque wrench
Reuse
Informational PurposesAn informational icon, calling your attention
Note
The bolt and nut will be tightened to specification during the Four Wheel Alignment (Check and Adjust) at the end of the Front Subframe Assembly (Remove and Install) procedure.
Bolt and nut that attaches the LH rear lower aft link to the knuckle
115 Nm (84.8 lbs-ft)
  • 21 mm socket
  • 21 mm ratcheting combination wrench
  • Flex head ratchet/flex head torque wrench
Reuse
Informational PurposesAn informational icon, calling your attention
Note
The bolt and nut will be tightened to specification during the Four Wheel Alignment (Check and Adjust) at the end of the Front Subframe Assembly (Remove and Install) procedure.
Bolt and nut that attach the LH rear damper assembly to the LH rear lower aft link
115 Nm (84.8 lbs-ft)
  • 21 mm socket
  • 21 mm combination wrench
  • Flex head ratchet/flex head torque wrench
Reuse
Bolt and nut that attaches the LH rear lower fore link to the subframe
76 Nm (56.0 lbs-ft)
  • 18 mm socket
  • 18 mm combination wrench
  • flex head ratchet
Bolt and nut that attaches the LH rear upper aft link to the subframe
134 Nm (98.8 lbs-ft)
  • 21 mm socket
  • 21 mm combination wrench
Bolt and nut that attaches the LH rear upper fore link to the subframe
84 Nm (61.9 lbs-ft)
  • 18 mm socket
  • 18 mm combination wrench
  • flex head ratchet
Bolt and nut that attaches the LH rear toe link to the subframe
85 Nm (62.7 lbs-ft)
  • 18 mm deep socket
  • 18 mm combination wrench
  • flex head ratchet
Nut that attaches the end link to the stabilizer bar
55 Nm (40.6 lbs-ft)
  • 15 mm socket
  • 5 mm hex socket
  • 15 mm flex head combination ratcheting wrench
  • flex head ratchet
LH front drive unit halfshaft nut
300 Nm (221.2 lbs-ft)
  • 32 mm deep impact socket
 Replace

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Open all doors and fully lower all windows.
  3. Connect to vehicle using Toolbox 3.0.
  4. Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
  5. In Toolbox, select the Actions/Autodiag tab, and then search for "Fill Drain".
  6. Click PROC_VCFRONT_X_THERMAL-FILL-DRAINSearch for routine in ToolboxThermal Fluid Fill/Drain, and then click Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    Click the "X" at the top right of the window once the routine is complete.
  7. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  8. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  9. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  10. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
  11. If equipped, remove the LH and RH rear wheel center caps. See Cap - Wheel (Remove and Replace).
  12. Loosen the LH and RH rear drive unit halfshaft nut.
    Tip: Use of the following tool(s) is recommended:
    • Long Breaker Bar
    • 32 mm deep impact socket
  13. Loosen the LH and RH rear wheel lug nuts.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only hand tools to remove or install the fasteners. Do not use impact or power tools.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use a 6 point socket. Do not use a 12 point socket or a specialty socket.
  14. Close all doors.
  15. Raise the vehicle fully.
  16. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  17. Remove the rear fascia diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  18. Remove the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  19. Lower and lock the vehicle at a comfortable working height.
  20. Remove the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  21. Remove and discard the bolts that attach the LH rear brake caliper bracket to the knuckle, and then hang the caliper bracket on the body with an S-hook. Repeat this step on the RH rear brake caliper.
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
  22. Remove and discard the bolt that attaches the rear LH ABS wheel speed sensor to the knuckle.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
  23. Release the clip and remove the grommet that attach the rear LH ABS wheel speed sensor cable to the rear knuckle and bracket.
  24. Install a spring compressor onto the LH rear coil spring.
    Tip: Use of the following tool(s) is recommended:
    • Gedore Spring Compressor
  25. Remove the bolts that attach the LH rear damper at the top mount.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 3 in extension
  26. Position a 3/4 ton support stand underneath the LH rear lower aft link and knuckle.
  27. Loosen the bolt and nut that attach the LH rear damper to the LH lower aft link.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm combination wrench
    • Flex head ratchet/flex head torque wrench
  28. Remove the bolt and nut that attach the LH rear aft lower link to the LH rear suspension knuckle.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm ratcheting combination wrench
    • Flex head ratchet/flex head torque wrench
  29. Remove the bolt and nut that attach the LH rear lower aft link to the subframe, and then with assistance, remove the lower aft link assembly.
    115 Nm (84.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm ratcheting combination wrench
  30. Remove and discard the LH rear halfshaft nut and washer.
    Tip: Use of the following tool(s) is recommended:
    • 32 mm deep impact socket
    • 6 in extension
  31. Remove the bolt that attach the LH rear brake rotor to the hub, but do not remove the rotor from the assembly.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 2 in extension
    • Ratchet/torque wrench
  32. Position the hub puller onto the LH rear hub assembly, and then secure the puller with the wheel lug nuts (x2) and hub puller washers (x2).
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • Flex head ratchet/flex head torque wrench
    • 6 in extension
  33. Rotate the hub puller counterclockwise to free the LH rear halfshaft from the LH rear hub splines.
    Tip: Use of the following tool(s) is recommended:
    • 17 mm deep socket
  34. Remove the hub puller tool from the LH rear hub assembly.
  35. Install the bolt that attaches the LH rear brake rotor to the hub.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 2 in extension
    • Ratchet/torque wrench
  36. Position a 3/4 ton support stand underneath the LH rear knuckle.
  37. Remove and discard the nut that attaches the LH rear stabilizer bar end link to the stabilizer bar, and then remove the bar from the end link.
    55 Nm (40.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 5 mm hex socket
    • 15 mm flex head combination ratcheting wrench
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the stabilizer up and down as needed to achieve the correct angle for removal. If necessary, use a pry bar for assistance.
  38. Remove the bolt and nut that attach the LH rear lower fore link to the knuckle.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm combination wrench
    • flex head ratchet
  39. Remove the bolt and nut that attach the LH rear upper aft link to the LH rear suspension knuckle.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm ratcheting combination flex head wrench
    • 6 in extension
  40. Remove the bolt and nut that attach the LH rear upper fore link to the LH rear suspension knuckle.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm ratcheting combination wrench
    • 3 in extension
  41. Remove the bolt and nut that attach the LH rear toe link to the LH rear suspension knuckle.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm ratcheting combination wrench
  42. With assistance, remove the LH rear knuckle, hub and rotor assembly from the vehicle.
  43. 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
  44. Hook the axle remover slide hammer on the 2 axle remover cable loops, and then use the slide hammer to release the halfshaft from the drive unit.
  45. With assistance, remove the LH rear drive unit halfshaft from the rear drive unit, and then install a halfshaft plug into the opening of the gearbox.
  46. Repeat step 21 through step 45 for the RH side of the vehicle.
  47. Fully raise and lock the vehicle.
  48. Remove the LH and RH rear wheel arch liners. See Wheel Arch Liner - Rear - LH (Non-Structural Pack) (Remove and Replace).
  49. Release the connector lock, and then disconnect the RH 12V subframe harness connector.
  50. Release the clip that attaches the subframe electrical harness to the body.
  51. Release the connector lock, and then disconnect the LH 12V subframe harness connectors.
  52. Release the clip that attaches the LH subframe electrical harness to the body.
  53. Remove the nut that attaches the rear drive unit ground strap to the body.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  54. Remove the rear stabilizer bar. See Stabilizer Bar - Rear (Remove and Replace).
  55. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  56. Position the coolant drain beneath the LH rear of the HV battery.
  57. Disconnect the rear drive unit inverter inlet hose from the rear of the HV battery, and then plug the male and female fittings.
  58. Position the coolant drain container beneath the LH rear drive unit area.
  59. Disconnect the coolant inlet hose from the rear drive unit, and then plug the hose.
  60. Position the coolant drain container beneath the RH rear of the HV battery.
  61. Release the clip and disconnect the coolant outlet hose to rear powertrain return coupling, and immediately plug the male and female fittings.
  62. Remove the coolant drain container from underneath the vehicle.
  63. Remove the nuts (x2) that attaches the HV battery to rear drive unit harness bracket to the HV battery.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
  64. Slide the release to unlock the HV battery rear drive unit connector handle of the rear drive unit to HV battery harness from the secured position.
  65. Fully raise the handle on the HV battery rear drive unit connector.
  66. Remove the HV battery rear drive unit connector from the HV battery header.
  67. Position the rear subframe lifting tool beneath the rear subframe.
  68. Attach an air hose to the rear subframe lifting tool.
  69. With an assistant, raise the rear subframe lifting tool to support the rear subframe.
  70. Loop the straps over the rear subframe, hook the ends of the straps to the metal rings, and then pull the straps tight to restrain the subframe to the rear subframe lifting tool.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower the vehicle to give more slack to connect the straps to the rings, if necessary.
  71. Release the fir tree clips that attach the coolant hoses to the LH shear plate.
  72. Remove the smaller bolts that attach the LH shear plate to the HV battery.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
  73. Remove and discard the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 6 in extension
  74. Hand-tighten the smaller bolts that attach the LH shear plate to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install the shear plate at this time.
  75. Repeat step 71 through step 74 for the RH shear plate.
  76. Remove and discard the bolts (x2) that attach the rear subframe to the body.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 6 in extension
  77. With an assistant, slowly lower the rear subframe lifting tool to remove the rear subframe from the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Assist with the routing of HV harnesses and coolant hoses through components so that they do not "catch".
  78. Disconnect the air supply from the rear subframe lifting tool.
  79. Move the rear subframe and rear subframe lifting tool away from the vehicle.
  80. Release the clip that attaches the rear drive unit inlet hose to the HV harness bracket, and then remove the hose from the rear subframe assembly.
  81. Remove the bolt that attaches the rear drive unit HV harness bracket to the rear drive unit.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  82. Slide the release to unlock the rear drive unit HV connector handle of the rear drive unit to HV battery harness from the secured position.
  83. Fully raise the handle on the rear drive unit HV connector.
  84. Remove the rear drive unit HV cable from the subframe assembly.
  85. Disconnect the electrical harness from the inverter low voltage connector.
  86. Release the clip that attaches the low voltage electrical harness to the inverter.
  87. Release the clips that attach the resolver electrical harness to the rear drive unit, and then disconnect the electrical connector.
  88. Disconnect the oil pump connector from the rear drive unit assembly.
  89. Position the drive unit stand underneath the gantry.
  90. Attach the drive unit sling tool to the rear drive unit.
  91. Attach the drive unit sling tool to the gantry.
  92. Raise the sling tool so that there is a slight tension on the cables.
  93. Remove the bolt that attaches the LH mount of the rear drive unit to the rear subframe.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  94. Remove the bolt that attaches the RH mount of the rear drive unit to the rear subframe.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  95. Remove the bolt that attaches rear of the rear drive unit to the rear subframe.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  96. With assistance, raise the drive unit sling tool to lift the rear drive unit out of the rear subframe.
  97. Move the subframe and lifting tool from underneath the drive unit.
  98. Remove the bolt and nut that attach the LH rear upper aft link to the subframe.
    134 Nm (98.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm combination wrench
  99. Remove the bolt and nut that attach the LH rear upper fore link to the subframe.
    84 Nm (61.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm combination wrench
    • flex head ratchet
  100. Remove the bolt and nut that attach the LH rear toe link to the subframe.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm deep socket
    • 18 mm combination wrench
    • flex head ratchet
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the eccentric bolt to find the correct position for removal.
  101. Remove the bolt and nut that attach the LH rear lower fore link to the subframe.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm combination wrench
    • flex head ratchet
  102. Repeat step 98 through step 101 for the RH side of the subframe assembly.
  103. Release the clips that attach the subframe harness to the bottom of the rear subframe.
  104. Release the clips (x9) that attach the subframe harness to the top of the rear subframe, and then remove the harness from the subframe.
  105. With assistance, release the straps that secures the subframe to lifting tool, and then remove the subframe from the lifting tool.

Install

  1. With assistance, install a new subframe into the lifting tool, and then secure the straps.
  2. Install the clips (x9) that attach the subframe harness to the top of the rear subframe.
  3. Install the clips that attach the subframe harness to the bottom of the rear subframe.
  4. Move the subframe and lifting tool beneath the drive unit.
  5. With assistance, lower the sling to install the rear drive unit into the subframe.
  6. Install and hand-tighten the bolt that attaches rear of the rear drive unit to the rear subframe.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  7. Install and hand-tighten the bolt that attaches the RH mount of the rear drive unit to the rear subframe.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  8. Install and hand-tighten the bolt that attaches the LH mount of the rear drive unit to the rear subframe.
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  9. Lower the drive unit sling to release tension in the cable.
  10. Remove the drive unit sling from the gantry.
  11. Remove the hooks (x3) that attaches the drive unit sling tool to the rear drive unit.
  12. Torque the LH, RH and rear motor mount bolts.
    80 Nm (59.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  13. Install the clips that attach the resolver electrical harness to the rear drive unit, and then connect the electrical connector.
  14. Connect the oil pump connector from the rear drive unit assembly.
  15. Install the clip that attaches the low voltage electrical harness to the inverter.
  16. Connect the electrical harness from the inverter low voltage connector.
  17. Install and hand-tighten the bolt and nut that attach the RH rear upper aft link to the subframe.
    134 Nm (98.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm combination wrench
  18. Install and hand-tighten the bolt and nut that attach the RH rear upper fore link to the subframe.
    84 Nm (61.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm combination wrench
    • flex head ratchet
  19. Install and hand-tighten the bolt and nut that attach the RH rear toe link to the subframe.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm deep socket
    • 18 mm combination wrench
    • flex head ratchet
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the eccentric bolt to find the correct position for removal.
  20. Install and hand-tighten the bolt and nut that attach the RH rear lower fore link to the subframe.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm combination wrench
    • flex head ratchet
  21. Repeat step 17 through step 20 for the LH side of the subframe assembly.
  22. Position the rear drive unit HV cable on the rear subframe.
  23. Fully raise the handle on the rear drive unit HV connector.
  24. Install the HV connector special tool onto the rear drive unit HV connector.
  25. Use both hands to firmly connect the rear drive unit HV connector to the rear drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  26. Remove the HV connector special tool from the rear drive unit HV connector.
  27. While pressing the rear drive unit HV connector onto the rear drive unit HV header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  28. Slide the release to lock the rear drive unit HV connector handle in the secured position.
  29. Verify that the rear drive unit HV connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  30. Install the bolt that attaches the HV harness bracket to the inverter.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  31. Connect the rear drive unit inlet hose to the inverter coolant coupling, and then fasten the spring clip.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Perform a push-pull test to verify that the hose is fully seated.
  32. Install the clip that attaches the rear drive unit inlet hose to the HV harness bracket.
  33. Position the subframe lifting tool and rear subframe underneath the vehicle.
  34. Connect the air line to the subframe lifting tool.
  35. With an assistant, slowly raise the rear drive unit and subframe into position.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Assist with the routing of HV harnesses and coolant hoses through components so that they are not pinched or broken.
  36. Hand-tighten the new bolts (x2) that attach the rear subframe to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    The tightening of the bolts will be performed later in this procedure.
  37. Remove the smaller bolts that attach the LH and RH shear plates to the body.

    LH shear plate bolts shown, RH similar

  38. Install the LH shear plate to the rear subframe and HV battery, and then hand-tighten a new bolt to attach the shear plate to the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    The tightening of the bolt will be performed later in this procedure.
  39. Hand-tighten the smaller bolts that attach the LH shear plate to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The tightening of the bolts will be performed later in this procedure.
  40. Repeat step 37 through step 39 for the RH side of the vehicle.
  41. Torque the smaller bolts that attach the LH and RH shear plates to the vehicle.
    For non-Structural Pack vehicles:
    35 Nm (25.8 lbs-ft)
    For Structural Pack vehicles:
    62 Nm (45.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
  42. Torque the large bolts that attach the LH and RH shear plates to the vehicle, and then mark them with a paint pen after torquing.
    130 Nm (95.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 6 in extension
  43. Tighten the bolts that attach the LH and RH rear subframe to the body, and then mark them with a paint pen after torquing.
    165 Nm (121.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 6 in extension
  44. Fasten the fir tree clips that attach the coolant hoses to the LH and RH shear plates.

    LH shear plate shown, RH shear plate similar

  45. Release the straps and lower the subframe lifting tool from the vehicle.
  46. Disconnect the air line from the subframe lifting tool, and then remove the tool from underneath the vehicle.
  47. Fully raise the handle on the HV battery rear drive unit harness connector.
  48. Install the HV connector special tool onto the HV battery rear drive unit connector.
  49. Use both hands to firmly connect the HV battery rear drive unit connector of the rear drive unit to HV battery harness to the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  50. Remove the HV connector special tool from the HV battery rear drive unit connector.
  51. While pressing the HV battery rear drive unit connector onto the HV battery header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  52. Slide the release to lock the HV battery rear drive unit connector handle in the secured position.
  53. Verify that the HV battery rear drive unit connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  54. Install the nut that attaches the rear drive unit HV electrical harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
  55. Position the coolant drain beneath the RH rear of the HV battery.
  56. Remove the hose plugs, and then connect coolant outlet hose to rear power train return hose.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Perform a push-pull test to verify that the hose is fully seated.
  57. Position the coolant drain underneath the LH rear of the HV battery.
  58. Remove the hose plugs, and then connect rear drive unit inverter inlet hose to the rear of HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Perform a push-pull test to verify that the hose is fully seated.
  59. Remove the coolant drain from underneath the vehicle.
  60. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  61. Install the rear stabilizer bar. See Stabilizer Bar - Rear (Remove and Replace).
  62. Install the bolt that attaches the rear drive unit ground strap to the body.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Reinstall the washer if the vehicle had this washer during removal.
  63. Fasten the LH subframe electrical harness barrel clip to the body.
  64. Connect the electrical connector for the LH side 12V subframe harness.
    Figure 2. LH side shown, RH similar
  65. Repeat steps 63 and 64 for the RH side of the vehicle.
  66. Partially lower and lock the vehicle to a comfortable working height.
  67. Remove the halfshaft plugs from the gearbox, and then with assistance, install the LH and RH front drive unit halfshafts into the front drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage or displace the oil seal.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the opening of the snap ring is facing towards the bottom of the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the front knuckle assembly aside to provide enough clearance to safely install the front drive unit halfshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    New front drive units come prefilled with gearbox fluid. Clean up any leaks during installation and top off the gearbox fluid as necessary. For more information, search for 1446276-00-B in the Service Tooling Catalog.
  68. Verify that the halfshafts are 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.
  69. Apply approximately 1 gram of Molykote M-77 Lubricant Paste only to the hub mating face on the outboard side of the LH rear drive unit halfshaft.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply any lubricant to the halfshaft splines. If lubricant is mistakenly applied, wipe the splines clean with a shop towel.
    Figure 3. Lubricate the area highlighted red
  70. Position a support stand underneath the RH rear suspension.
  71. With assistance, install the RH rear halfshaft into the RH knuckle, hub and rotor assembly, and then position the knuckle assembly onto the support stand.
  72. Install and hand-tighten the bolt and nut that attach the RH rear upper aft link to the RH rear suspension knuckle.
    Figure 4. LH side shown, RH similar
  73. Install and hand-tighten the bolt and nut that attach the RH rear upper fore link to the RH rear suspension knuckle.
    Figure 5. LH side shown, RH similar
  74. Install and hand-tighten the bolt and nut that attach the RH toe link to the RH rear suspension knuckle.
    Figure 6. LH side shown, RH similar
  75. Install and hand-tighten the bolt and nut that attach the RH rear lower fore link to the RH rear suspension knuckle.
    Figure 7. LH side shown, RH similar
  76. With assistance, position the RH rear lower aft link assembly to the subframe, and then install and hand-tighten the bolt and nut that attach the assembly to the subframe.
    115 Nm (84.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm ratcheting combination wrench
  77. Install and hand-tighten the bolt and nut that attach the RH rear aft lower link to the RH rear suspension knuckle.
    Figure 8. LH side shown, RH similar
  78. Install the bolts that attach the RH rear damper at the top mount.
    41 Nm (30.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 3 in extension

    LH shown; RH similar.

  79. Position the RH rear end link into the stabilizer bar, and then install a new nut that attaches the end link to the stabilizer bar.
    55 Nm (40.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 5 mm hex socket
    • 15 mm flex head combination ratcheting wrench
    • flex head ratchet
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the stabilizer up and down as needed to achieve the correct angle for installation.
  80. Install a new nut and washer that attach the RH rear halfshaft to the LH rear hub assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Nut will be torqued at a later step.
    Tip: Use of the following tool(s) is recommended:
    • 32 mm deep impact socket
    • 6 in extension
  81. Remove the support stand from beneath the RH rear suspension.
  82. Position the RH rear brake caliper onto the RH rear knuckle, and then install new bolts that attach the caliper to the knuckle.
    83 Nm (61.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
  83. Install the grommet that attaches the rear RH ABS wheel speed sensor cable to the rear RH knuckle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Perform a push-pull check on the grommet to make sure it is securely fastened to the knuckle.
    Figure 9. LH shown, RH similar
  84. Install the rear RH ABS wheel speed sensor to the knuckle, and then install a new bolt to attach the sensor to the knuckle.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 6 in extension
    Figure 10. LH shown, RH similar
  85. Repeat step 67 through step 84 for the LH side of the vehicle.
  86. Remove the bolt that attaches the RH rear brake rotor to the hub, but do not remove the rotor from the assembly.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 2 in extension
    • Ratchet/torque wrench
  87. Hand-tighten the nuts that attach the rear hub jack adapter to the LH rear hub.
  88. Position a support stand underneath the LH lower rear control arm, and then raise the support stand to simulate vehicle at ride height.
  89. Use the rear ride height torque gauge to verify that the suspension is set within ride height specification.
    Informational PurposesAn informational icon, calling your attention
    Note
    Might need to adjust the support stand or spring compressor tool slightly.
  90. Measure the distance between the bottom of the quarter panel to the center of the rear axle to make sure that the rear suspension is set to ride height: The distance should measure 427 mm.
  91. Tighten the bolt and nut that attach the RH rear upper aft link to the subframe.
    134 Nm (98.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm combination wrench
    Figure 11. LH shown, RH similar
  92. Tighten the bolt and nut that attach the RH rear upper fore link to the subframe.
    84 Nm (61.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm combination wrench
    • flex head ratchet
    Figure 12. LH shown, RH similar
  93. Tighten the bolt and nut that attach the RH rear toe link to the subframe.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm deep socket
    • 18 mm combination wrench
    • flex head ratchet
    Figure 13. LH shown, RH similar
  94. Tighten the bolt and nut that attach the RH rear lower fore link to the subframe.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm combination wrench
    • flex head ratchet
    Figure 14. LH shown, RH similar
  95. Tighten the bolt and nut that attach the RH rear lower aft link to the subframe.
    115 Nm (84.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm combination wrench
    Figure 15. LH shown, RH similar
  96. Tighten the bolt and nut that attach the RH rear damper assembly to the RH rear lower aft link.
    115 Nm (84.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm combination wrench
    • Flex head ratchet/flex head torque wrench
    Figure 16. LH shown, RH similar
  97. Tighten the bolt and nut that attach the RH rear lower aft link to the RH rear suspension knuckle. Mark the bolt with a paint pen.
    115 Nm (84.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm ratcheting combination wrench
    • Flex head ratchet/flex head torque wrench
    Figure 17. LH shown, RH similar
  98. Tighten the bolt and nut that attach the RH rear upper aft link to the RH rear suspension knuckle. Mark the bolt with a paint pen.
    134 Nm (98.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    • 21 mm ratcheting combination flex head wrench
    • 6 in extension
    Figure 18. LH shown, RH similar
  99. Tighten the bolt and nut that attach the RH rear upper fore link to the RH rear suspension knuckle. Mark the bolt with a paint pen.
    84 Nm (61.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm ratcheting combination wrench
    • 3 in extension
    Figure 19. LH shown, RH similar
  100. Tighten the bolt and nut that attach the RH toe link to the RH rear suspension knuckle. Mark the bolt with a paint pen.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm ratcheting combination wrench
    Figure 20. LH shown, RH similar
  101. Tighten the bolt and nut that attach the RH rear lower fore link to the RH rear suspension knuckle. Mark the bolt with a paint pen.
    76 Nm (56.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
    • 18 mm ratcheting combination wrench
    • Flex head ratchet/flex head torque wrench
    Figure 21. LH shown, RH similar
  102. Tighten the nut that attaches the end link to the stabilizer bar. Mark the nut with a paint pen.
    55 Nm (40.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 5 mm hex socket
    • 15 mm flex head combination ratcheting wrench
    • flex head ratchet
  103. Remove the support stand front underneath the RH suspension.
  104. Remove the hub jack adapter from the RH rear hub.
  105. Install the bolt that attaches the RH rear brake rotor to the RH rear hub.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 2 in extension
    • Ratchet/torque wrench
    Figure 22. LH shown, RH similar
  106. Remove the spring compressor from the RH rear coil spring.
  107. Repeat step 86 through step 106 for the LH side of the vehicle.
  108. Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  109. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  110. Install the rear wheels. See Wheel Assembly (Remove and Install).
  111. Torque the LH rear halfshaft nut.
    300 Nm (221.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 32 mm deep impact socket
  112. If equipped, install the LH front wheel center cap. See Cap - Wheel (Remove and Replace).
  113. Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).
  114. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  115. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  116. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  117. 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.
  118. Restore the driver and front passenger seats back to their original positions.