2026-09-01

Drive Unit - Rear (4DU) (Structural Pack) (Remove and Replace)

Correction code 40011022 FRT 4.14 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-09-01: Released new procedure.
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.

Install

  1. Position the new rear drive unit and crate it underneath gantry.
  2. Release the protective covers from new rear drive unit and transfer them onto the old drive unit.
  3. Secure the drive unit sling onto the new drive unit and raise the gantry hook to put tension on the sling.
  4. Remove the bolts that secure the rear drive unit to the crate.
    Note
    Use of the following tool(s) is recommended:
    • 19 mm socket
    • Ratchet/torque wrench
  5. Lift the rear drive unit off of the protective surface and position the rear subframe and subframe lift underneath the drive unit.
  6. With the help of an assistant, use the gantry to lower the rear drive unit sling tool, guide halfshafts into the rear drive unit, and lower the rear drive unit into the rear subframe.
  7. Lower the rear drive unit sling tool so as to install and hand tighten the bolt that attaches the rear drive unit to the rear of the rear subframe.
  8. Install and hand tighten the bolt that attaches the rear drive unit to the RH side of the rear subframe.
  9. Install and hand tighten the bolt that attaches the rear drive unit to the LH side of the rear subframe.
  10. Lower the drive unit sling tool to release tension in the cables, and then remove the sling tool from the rear drive unit.
  11. Tighten the rear drive unit mount bolts (x3).
    80 Nm (59.0 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • 18 mm socket
    • Flex head ratchet/flex head torque wrench
  12. Use the shackles (x3) to attach the drive unit sling tool to the old rear drive unit.
  13. Use the gantry to raise the old rear drive unit off of the protective surface and position the drive unit over the rear drive unit crate.
  14. With the help of an assistant, use the gantry to lower the old rear drive unit into the rear drive unit crate.
  15. Install and hand tighten the bolts (x3) that attach the old rear drive unit to the rear drive unit crate.
    Note
    Use of the following tool(s) is recommended:
    • 19 mm socket
    • Cordless Ratchet/Impact Driver
  16. Remove the drive unit sling tool from the old rear drive unit.
  17. Remove the drive unit sling tool from the gantry.
  18. Prepare the rear drive unit crate for MRB.
  19. With the help of an assistant, slightly rotate the LH halfshaft so as to align the splines of the halfshaft to those in the rear drive unit, lift up on the LH rear knuckle to help move the halfshaft into the drive unit, and then apply force to seat the halfshaft in the drive unit.
    Note
    If the halfshaft binds, back the halfshaft out, rotate it slightly, and try again.
    CAUTION
    When installing the halfshaft(s) into the drive unit:
    • Make sure that the opening of the snap ring is facing towards the bottom of the drive unit.
    • Do not damage or displace the oil seal.
    • Verify that the halfshaft is fully seated:
      • Carefully push the halfshaft into the drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
      • There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
      • Pull on the inner halfshaft cup to confirm that the circlip is locked into place. If the halfshaft detaches from the drive unit then reinstall the halfshaft and then test that it is fully seated.
  20. Install the LH rear toe link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
  21. Install the LH rear upper fore link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
  22. Install the LH rear upper aft link to the LH rear knuckle, and then install and hand-tighten the nut and bolt that attach the link to the knuckle.
  23. Fasten the grommet that attaches the LH rear wheel speed sensor harness to LH rear knuckle.
  24. Install the LH rear wheel speed sensor to LH rear knuckle, and then install the bolt that attaches the sensor to knuckle.
    5 Nm (3.7 lbs-ft)
  25. Repeat step 9 through step 14 on the RH side of the rear subframe assembly.
  26. Connect the rear subframe harness to the resolver connector, push the red tab to secure, and then fasten the clips (x2) that attach the subframe harness to the rear drive unit.
  27. Connect the rear subframe harness to the oil pump connector, and then push the red tab to secure.
  28. Manuever the rear drive unit inverter outlet to heat exchanger hose in between the rear drive unit and rear subframe, and then fasten the clips (x2) that attach the hose to the drive unit.
  29. Connect the rear drive unit inverter to heat exchanger hose to the rear drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  30. Connect the rear drive unit inverter to heat exchanger hose to the rear drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  31. Fasten the clips (x2) that attach the rear drive unit inverter outlet to heat exchanger hose to the rear drive unit.
  32. Manuever the rear drive unit coolant outlet hose in between the rear drive unit and rear subframe, and then fasten the clips (x3) that attach the hose to drive unit.
  33. Connect the rear drive unit coolant outlet hose to the rear drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  34. Install the rear drive unit ground strap to the rear drive unit, and then install the bolt that attaches the ground strap to the drive unit.
    6 Nm (4.4 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  35. Fasten the clip that attaches the rear drive unit ground strap to the rear subframe.
  36. Position the rear subframe and rear drive unit assembly under the vehicle.
  37. Connect the air supply to the subframe lifting tool.
  38. Carefully raise the subframe and rear drive unit assembly until they are up against the body.
    CAUTION
    Do not damage hoses or harnesses while raising the subframe.
  39. Install and hand-tighten a new RH rear subframe bolt to attach the rear subframe to the body.
  40. Install and hand-tighten a new LH rear subframe bolt to attach the rear subframe to the body.
  41. Install the RH shear plate to the rear subframe, and then install a new large bolt to attach the RH shear plate and rear subframe to the body.
  42. Install and hand-tighten the small bolts (x2) that attach the RH shear plate to the HV battery.
  43. Install the LH shear plate to the rear subframe, and then install a new large bolt to attach the LH shear plate and rear subframe to the body.
  44. Install and hand-tighten the small bolts (x2) that attach the LH shear plate to the HV battery.
  45. Use a pry bar to shimmy the rear subframe with respect to the body, so that the subframe mounting bolts are centered in the tracings, and the witness marks align where the subframe contacts the body.
  46. Tighten the RH rear subframe bolt that attaches the rear subframe to the body, and then mark the bolt after tightenting.
    160 Nm (118.0 lbs-ft)
  47. Tighten the LH rear subframe bolt that attaches the rear subframe to the body, and then mark the bolt after tightenting.
    160 Nm (118.0 lbs-ft)
  48. Tighten large bolt that attaches the LH shear plate and rear subframe to the body, and then mark the bolt after tightenting.
    130 Nm (95.9 lbs-ft)
  49. Tighten large bolt that attaches the RH shear plate and rear subframe to the body, and then mark the bolt after tightenting.
    130 Nm (95.9 lbs-ft)
  50. Tighten the small bolts (x2) that attach the RH shear plate to the HV battery.
    35 Nm (25.8 lbs-ft)
    Note
    Some vehicles are equipped with self-tapping bolts in bolt position #8-15 from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
  51. Tighten the small bolts (x2) that attach the LH shear plate to the HV battery.
    35 Nm (25.8 lbs-ft)
    Note
    Some vehicles are equipped with self-tapping bolts in bolt position #8-15 from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
  52. Release the straps (x3) that attach the rear subframe to the subframe lifting tool.
  53. Lower the subframe lifting tool, and move it out from under the vehicle.
  54. Remove all items from pockets and ensure not wearing metal items.
  55. Put on HV insulating gloves and leather over gloves.
  56. Install the rear drive unit HV harness in and up between the rear subframe and the HV battery.
    Note
    Rotate the harness as it is installed to allow access for the bracket.
  57. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery header, secure the release lever to the closed position, and then slide the red connector locking tab.
  58. Install the nut(s) that attach(es) the rear drive unit HV harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
  59. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the rear drive unit inverter HV header, secure the release lever to the closed position, and then slide the connector locking tab.
  60. Remove leather over gloves and HV insulating gloves.
  61. Install the bolt that attaches the rear drive unit HV harness bracket to the rear drive unit inverter.
    6 Nm (4.4 lbs-ft)
  62. Inspect the rear subframe electrical harness logic connector and the rear drive unit inverter logic connector for coolant, and use shop air and a clean dry shop towel to remove any coolant from the connectors.
  63. Connect the rear subframe electrical harness to the rear drive unit inverter logic connector, raise the handle upward, and fasten the locking tab.
  64. Fasten the clip that attaches the rear subframe electrical harness to the rear drive unit inverter.
  65. Position a coolant drain collector underneath the LH rear of the HV battery.
  66. Install the rear drive unit inverter inlet hose in and up between the rear subframe and the HV battery.
  67. Fasten the clip that attaches the rear drive unit inverter inlet hose to rear drive unit HV harness.
  68. Remove the plugs from the fittings, immediately connect the rear drive unit inverter inlet hose to the rear drive unit inverter, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  69. Remove the plugs from the fittings, immediately connect the rear drive unit inverter inlet hose to the HV battery, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  70. Position the coolant drain collector underneath the RH rear of the HV battery.
  71. Connect the RDU oil cooler outlet pipe.
  72. Remove the coolant drain collector from under the vehicle.
  73. Install the rear stabilizer bar to the rear subframe, and then install new bolts (x4) to attach the stabilizer bar to the subframe.
    30 Nm (22.1 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • 11 mm socket
    • 3 in extension
    • Ratchet/torque wrench
  74. Install the LH rear stabilizer bar end link into the rear stabilizer bar.
    Note
    Move the stabilizer bar up and down to ease installation of the end link.
  75. Install a new nut to attach the LH rear stabilizer bar end link to the rear stabilizer bar and mark the bolt with a paint pen.
    55 Nm (40.6 lbs-ft)
    Note
    Use a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
  76. Install the RH rear stabilizer bar end link into the rear stabilizer bar.
    Note
    Move the stabilizer bar up and down to ease installation of the end link.
  77. Install a new nut to attach the RH rear stabilizer bar end link to the rear stabilizer bar and mark the nut with a paint pen.
    55 Nm (40.6 lbs-ft)
    Note
    Use a 5mm allen wrench to prevent the ball joint stud from turning and damaging the ball joint.
  78. Fasten the clip that attaches the rear subframe harness to the body on the LH side.
  79. Connect electrical harness to the rear subframe harness LH connector and then fasten the red locking tab.
  80. Fasten the clip that attaches the rear subframe harness to the body on the RH side.
  81. Connect electrical harness to the rear subframe harness RH connector and then fasten the red locking tab.
  82. Install the rear drive unit ground strap to the body, and then install the nut that attaches the ground strap to the body.
    10 Nm (7.4 lbs-ft)
  83. Install the LH rear strut to the body at the LH top mount, and then install the bolts (x2) that attach the strut to the body.
    41 Nm (30.2 lbs-ft)
  84. Remove the S-Hook, install the LH rear brake caliper to the LH rear knuckle, and then install new bolts (x2) to attach the caliper to the knuckle.
    83 Nm (61.2 lbs-ft)
  85. Remove the bolt that attaches the LH rear brake rotor to the hub.
  86. Install the hub jack adapter onto the LH rear hub and hand-tighten the lug nuts (x5).
  87. Use an underhoist stand to support the hub jack adapter and simulate the LH rear suspension at ride height.
  88. Use the rear ride height torque gauge to verify the LH rear suspension is set to ride height specification.
    Note
    It may be necessary to slightly adjust the underhoist stand or Gedore spring compressor tool.
  89. The distance between the bottom of the quarter panel and the center of the rear axle should be 427 mm when the rear suspension is set to ride height.
    Note
    It may be necessary to slightly adjust the underhoist stand or Gedore spring compressor tool.
  90. Tighten the bolt and nut that attach the LH rear upper aft link to the knuckle, and then mark the fasteners with a paint pen after tightening
    134 Nm (98.8 lbs-ft)
  91. Tighten the bolt and nut that attach the LH rear upper fore link to the knuckle, and then mark the fasteners with a paint pen after tightening
    84 Nm (61.9 lbs-ft)
  92. Tighten the bolt and nut that attach the LH rear toe link to the knuckle, and then mark the fasteners with a paint pen after tightening
    76 Nm (56.0 lbs-ft)
  93. Tighten the bolt and nut that attach the LH rear lower fore link to the knuckle, and then mark the fasteners with a paint pen after tightening
    76 Nm (56.0 lbs-ft)
  94. Remove the underhoist stand from underneath the LH rear suspension.
  95. Remove the lug nuts (x5) that attach the hub jack adapter, and then remove the hub jack adapter from the vehicle.
  96. Install the bolt that attaches the LH rear brake rotor to the hub.
    5 Nm (3.7 lbs-ft)
  97. Remove the Gedore spring compressor from the LH rear coil spring.
    Note
    Refer to the Tooling Profile for additional information.
  98. Repeat step 73 through step 87 for the RH side of the vehicle.
  99. Install the rear diffuser. See Diffuser - Rear Fascia (Remove and Replace).
  100. Install the clips that secure the LH and RH rear wheel liners to rear fascia assembly.
    Figure 1. LH shown; RH similar
    Figure 2. LH shown; RH similar
  101. Install the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  102. Install the LH and RH rear suspension covers. See Cover - Rear Suspension - LH (Remove and Replace).
  103. Lower the vehicle partially and set onto locks.
  104. Install the LH and RH rear wheels. See Wheel Assembly (Remove and Install).
  105. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  106. Connect the LV power. See 12V/LV Power (Disconnect and Connect).
  107. Connect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  108. Connect a laptop with Toolbox to the vehicle. See Toolbox (Connect and Disconnect).
  109. Run PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Service Mode:
    • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    via Toolbox:(link)    .
  110. Run PROC_PMR_X_WRITE-DRIVE-TYPEvia Service Mode Plus:Drive Unit ➜ Rear Drive Unit Replacement ➜ Write Drive Typevia Toolbox:(link)
  111. Run PROC_EPB_X_SERVICE-MODEvia Service Mode:
    • Chassis ➜ Brakes ➜ EPB Service Mode
    • Chassis ➜ Brakes ➜ EPB Service Mode
    via Service Mode Plus:Drive Unit ➜ Rear Drive Unit Replacement ➜ Release / Re-Engage Emergency Parking Brakevia Toolbox:(link)    .
  112. Run UPDATE_CAN-REDEPLOYvia Service Mode Plus:
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
    • Thermal ➜ HVAC ➜ CAN Redeploy
    • chassis ➜ DPB Post Replacement ➜ CAN Redeploy
    • chassis ➜ ESP Post Replacement ➜ CAN Redeploy
    • chassis ➜ IDB Post Replacement ➜ CAN Redeploy
    • chassis ➜ RCU Post Replacement ➜ CAN Redeploy
    • chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
    • chassis ➜ IBST Replacement Panel ➜ CAN Redeploy
    via Toolbox:(link)
  113. Disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  114. Run PROC_DI_X_PAIR-IMMOBILIZER-AND-VEHICLE-ODOMETERvia Service Mode Plus:
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Immobilizer/ODO Pairing
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Pair Immobilizer and Vehicle Odometer
    via Toolbox:(link)    .
  115. Run TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)    .
  116. Add coolant to the reservoir as necessary, and install the reservoir cap.
  117. Run TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Service Mode:Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
    via Toolbox:(link)    .
  118. Disconnect the laptop with Toolbox from the vehicle. See Toolbox (Connect and Disconnect).
  119. Install the HEPA duct. See Duct - HEPA (Remove and Replace).
  120. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
  121. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  122. Disable Service Mode. See Service Mode.
  123. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  124. Install the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
  125. Perform a validation test drive after repair: drive at a minimum speed of 25 mph in a straight line, check for excessive pull, verify the steering wheel is centered when driving straight, and determine whether an alignment is recommended.
    Note
    Add correction code 00040100 as needed.