Drive Unit - Rear (Remove and Install)

Correction code 4001100140011001
  • 1099645-00-BFixture, Subframe, Model 3
  • 1130279-00-ALifting Sling, Drive Unit, Model 3 (NA, APAC)
  • 1130481-00-AAdapter, Subframe, Body Shop, Model 3
  • 1096075-00-ATool, Hub Puller, Hydraulic
  • 1133386-00-ATool, Axle Extraction, Model 3
  • 1140311-00-ALever Lock, HV Connector, Model 3
  • 1446276-00-BKit, Drive Unit Dipstick, Model 3

SPECIAL TOOLS

Fixture, Subframe, Model 3 (1099645-00-B)
Lifting Sling, Drive Unit, Model 3 (NA, APAC) (1130279-00-A)
Adapter, Subframe, Body Shop, Model 3 (1130481-00-A)
Tool, Hub Puller, Hydraulic (1096075-00-A)
Tool, Axle Extraction, Model 3 (1133386-00-A)
Lever Lock, HV Connector, Model 3 (1140311-00-A)
Kit, Drive Unit Dipstick, Model 3 (1446276-00-B)
Parent topic: 4001 - Rear Drive Unit Assembly

Remove

  1. Remove the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
  2. Disconnect the electrical harness from the inverter low voltage connector.
  3. Release the clip that attaches the low voltage electrical harness to the inverter.
  4. Release the clip, disconnect the rear drive unit inlet hose from the inverter coolant inlet, and then plug the inlet.
  5. Release the clip that attaches the rear drive unit inlet hose to the HV harness bracket, and then remove the hose from the rear drive unit.
  6. Remove the bolt that attaches the HV harness bracket to the inverter.
  7. Slide the release to unlock the HV harness connector.
  8. Lift the handle on HV harness connector, disconnect the harness from the inverter connector, and then remove the harness from the rear drive unit.
  9. Drain the fluid from the rear drive unit. See Gearbox Fluid - Rear Drive Unit (Drain and Refill).
  10. Release the clip that attaches the LH rear ABS wheel speed sensor connector to the subframe, and then disconnect the subframe harness from the connector.
    Tip: Use a mechanical pickup tool to hold the connector in place, and then release the connector clip with a screwdriver.
  11. Release the clip and remove the grommet that attach the rear LH ABS wheel speed sensor cable to the rear knuckle and bracket.
  12. Remove and discard the bolt that attaches the rear LH ABS wheel speed sensor to the knuckle, and then remove the sensor from the knuckle.
  13. Remove and discard the nut, and then remove the washer that attach the LH halfshaft to the hub assembly.
  14. Remove the bolt that attaches the LH rear brake rotor to the hub.
    Note: Remove the lug nut previously installed for early production vehicles.
  15. Install the hub puller onto the LH rear rotor, and then install and hand-tighten the puller washers (x5) and the lug nuts (x5) onto the rotor studs.
  16. Use the hub puller to free the LH rear halfshaft from the hub splines.
    Note: The LH rear halfshaft is removed in a later step.
  17. Remove the lug nuts (x5) and the puller washers (x5) from the LH rear rotor studs, and then remove the hub puller from the rotor.
  18. Install the bolt that attaches the LH brake rotor to the hub.
    Torque 5 Nm
    Note: Reinstall the lug nut previously installed for early production vehicles.
  19. Remove the bolt and nut that attach the LH upper aft link to the knuckle.
  20. Remove the bolt and nut that attach the LH upper fore link to the knuckle.
  21. Remove the bolt and nut that attach the LH rear toe link to the knuckle.
  22. Remove the LH rear halfshaft from the knuckle and hub assembly.
  23. With an assistant, release the LH rear halfshaft from the rear drive unit.
    Note: Set the LH rear halfshaft on the LH aft lower control arm.
  24. Remove the LH halfshaft from the rear drive unit, and then install a halfshaft plug into the opening of the gearbox.
  25. Repeat step 10 through step 24 on the RH side of the rear drive unit.
  26. Disconnect the electrical harness from the resolver connector.
  27. Disconnect the electrical harness from the oil pump connector.
  28. Attach the drive unit sling tool to the rear drive unit.
  29. Position the drive unit stand underneath the gantry.
  30. Attach the drive unit sling tool to the gantry.
  31. Raise the sling tool so that there is a slight tension on the cables.
  32. Remove the bolt and nut that attach the LH mount of the rear drive unit to the rear subframe.
  33. Remove the bolt and nut that attach the RH bushing of the rear drive unit to the rear subframe.
  34. Remove the bolt and nut that attach the rear bushing of the rear drive unit to the rear subframe.
  35. Raise the drive unit sling tool to lift the rear drive unit out of the rear subframe.
  36. Lower the rear drive unit into an empty crate or pallet.
  37. Remove the drive unit sling tool from the rear drive unit.
1Remove the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
2Disconnect the electrical harness from the inverter low voltage connector.
3Release the clip that attaches the low voltage electrical harness to the inverter.
4Release the clip, disconnect the rear drive unit inlet hose from the inverter coolant inlet, and then plug the inlet.
5Release the clip that attaches the rear drive unit inlet hose to the HV harness bracket, and then remove the hose from the rear drive unit.
6Remove the bolt that attaches the HV harness bracket to the inverter.
7Slide the release to unlock the HV harness connector.
8Lift the handle on HV harness connector, disconnect the harness from the inverter connector, and then remove the harness from the rear drive unit.
9Drain the fluid from the rear drive unit. See Gearbox Fluid - Rear Drive Unit (Drain and Refill).
10Release the clip that attaches the LH rear ABS wheel speed sensor connector to the subframe, and then disconnect the subframe harness from the connector.
Tip: Use a mechanical pickup tool to hold the connector in place, and then release the connector clip with a screwdriver.
11Release the clip and remove the grommet that attach the rear LH ABS wheel speed sensor cable to the rear knuckle and bracket.
12Remove and discard the bolt that attaches the rear LH ABS wheel speed sensor to the knuckle, and then remove the sensor from the knuckle.
13Remove and discard the nut, and then remove the washer that attach the LH halfshaft to the hub assembly.
14Remove the bolt that attaches the LH rear brake rotor to the hub.
Note: Remove the lug nut previously installed for early production vehicles.
15Install the hub puller onto the LH rear rotor, and then install and hand-tighten the puller washers (x5) and the lug nuts (x5) onto the rotor studs.
16Use the hub puller to free the LH rear halfshaft from the hub splines.
Note: The LH rear halfshaft is removed in a later step.
17Remove the lug nuts (x5) and the puller washers (x5) from the LH rear rotor studs, and then remove the hub puller from the rotor.
18Install the bolt that attaches the LH brake rotor to the hub.
Torque 5 Nm
Note: Reinstall the lug nut previously installed for early production vehicles.
19Remove the bolt and nut that attach the LH upper aft link to the knuckle.
20Remove the bolt and nut that attach the LH upper fore link to the knuckle.
21Remove the bolt and nut that attach the LH rear toe link to the knuckle.
22Remove the LH rear halfshaft from the knuckle and hub assembly.
23With an assistant, release the LH rear halfshaft from the rear drive unit.
Note: Set the LH rear halfshaft on the LH aft lower control arm.
24Remove the LH halfshaft from the rear drive unit, and then install a halfshaft plug into the opening of the gearbox.
25Repeat step 10 through step 24 on the RH side of the rear drive unit.
26Disconnect the electrical harness from the resolver connector.
27Disconnect the electrical harness from the oil pump connector.
28Attach the drive unit sling tool to the rear drive unit.
29Position the drive unit stand underneath the gantry.
30Attach the drive unit sling tool to the gantry.
31Raise the sling tool so that there is a slight tension on the cables.
32Remove the bolt and nut that attach the LH mount of the rear drive unit to the rear subframe.
33Remove the bolt and nut that attach the RH bushing of the rear drive unit to the rear subframe.
34Remove the bolt and nut that attach the rear bushing of the rear drive unit to the rear subframe.
35Raise the drive unit sling tool to lift the rear drive unit out of the rear subframe.
36Lower the rear drive unit into an empty crate or pallet.
37Remove the drive unit sling tool from the rear drive unit.

Install

  1. Attach the drive unit sling tool to the new rear drive unit.
  2. Raise the new rear drive unit out of the crate.
  3. Move the new rear drive unit over the rear subframe.
  4. With an assistant, lower the drive unit sling tool to install the new rear drive unit into the rear subframe.
  5. Install and hand-tighten the bolt and nut that attach the rear bushing of the rear drive unit to the rear subframe.
  6. Install and hand-tighten the bolt and nut that attach the RH bushing of the rear drive unit to the rear subframe.
  7. Install and hand-tighten the bolt and nut that attach the LH mount of the rear drive unit to the rear subframe.
  8. Lower the drive unit sling tool to release the tension on the cables.
  9. Remove the drive unit sling tool from the gantry.
  10. Remove the drive unit sling tool from the rear drive unit.
  11. Tighten the LH mount, RH bushing, and rear bushing bolts and nuts that attach the rear drive unit to the rear subframe.
    Torque 70 Nm
  12. Connect the electrical harness to the oil pump connector.
  13. Connect the electrical harness to the resolver connector.
  14. Remove the halfshaft plug from the gearbox, and then install the LH halfshaft to the rear drive unit.
    Note: New drive units come prefilled with gearbox fluid that might leak out of the drive unit during this step. Make sure to clean up any leakage.
    Note: Set the LH halfshaft on the aft lower control arm.
  15. Install the LH halfshaft to the hub and knuckle assembly.
  16. With an assistant, hand-tighten the bolt and nut that attach the LH toe link to the knuckle.
    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.
  17. With an assistant, hand-tighten the bolt and nut that attach LH upper fore link to the knuckle.
    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.
  18. With an assistant, hand-tighten the bolt and nut that attach the upper aft link to the knuckle.
    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.
  19. Install the washer, and install a new nut to attach the halfshaft to the LH rear hub.
    Torque 245 Nm
  20. Install the rear LH ABS wheel speed sensor to the knuckle, and then install a new bolt to attach the sensor to the knuckle.
    Torque 5 Nm
  21. Fasten the clip and install the grommet that attach the rear LH ABS wheel speed sensor cable to the rear LH knuckle and bracket.
    Caution:
    Perform a push-pull check on the clip and grommet to make sure they are securely fastened to the knuckle and bracket.
  22. Connect the subframe harness to the rear LH ABS wheel speed sensor connector, and then fasten the clip that attaches the connector to the rear subframe.
  23. Repeat step 14 through 22 on the RH side of the rear drive unit.
  24. Fully raise the handle on the rear drive unit HV electrical harness.
  25. Attach the HV connector lever lock onto the back of the HV electrical harness.
  26. Firmly connect the HV electrical harness to the inverter connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  27. While pressing the harness to the connector, remove the HV connector lever lock.
  28. While pressing the harness to the connector, fully lower the handle.
  29. Slide the release to lock the HV electrical harness.
  30. Install the bolt that attaches the HV harness bracket to the inverter.
    Torque 6 Nm
  31. Connect the rear drive unit inlet hose to the inverter coolant inlet, and then fasten the clip.
    Caution:
    Perform a push-pull test to verify that the hose is fully seated.
  32. Fasten the clip that attaches the rear drive unit inlet hose to the HV harness bracket.
  33. Connect the electrical harness to the inverter low voltage connector.
  34. Fasten the clip that attaches the low voltage electrical harness to the inverter.
  35. Install the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
1Attach the drive unit sling tool to the new rear drive unit.
2Raise the new rear drive unit out of the crate.
3Move the new rear drive unit over the rear subframe.
4With an assistant, lower the drive unit sling tool to install the new rear drive unit into the rear subframe.
5Install and hand-tighten the bolt and nut that attach the rear bushing of the rear drive unit to the rear subframe.
6Install and hand-tighten the bolt and nut that attach the RH bushing of the rear drive unit to the rear subframe.
7Install and hand-tighten the bolt and nut that attach the LH mount of the rear drive unit to the rear subframe.
8Lower the drive unit sling tool to release the tension on the cables.
9Remove the drive unit sling tool from the gantry.
10Remove the drive unit sling tool from the rear drive unit.
11Tighten the LH mount, RH bushing, and rear bushing bolts and nuts that attach the rear drive unit to the rear subframe.
Torque 70 Nm
12Connect the electrical harness to the oil pump connector.
13Connect the electrical harness to the resolver connector.
14Remove the halfshaft plug from the gearbox, and then install the LH halfshaft to the rear drive unit.
Note: New drive units come prefilled with gearbox fluid that might leak out of the drive unit during this step. Make sure to clean up any leakage.
Note: Set the LH halfshaft on the aft lower control arm.
15Install the LH halfshaft to the hub and knuckle assembly.
16With an assistant, hand-tighten the bolt and nut that attach the LH toe link to the knuckle.
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.
17With an assistant, hand-tighten the bolt and nut that attach LH upper fore link to the knuckle.
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.
18With an assistant, hand-tighten the bolt and nut that attach the upper aft link to the knuckle.
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.
19Install the washer, and install a new nut to attach the halfshaft to the LH rear hub.
Torque 245 Nm
20Install the rear LH ABS wheel speed sensor to the knuckle, and then install a new bolt to attach the sensor to the knuckle.
Torque 5 Nm
21Fasten the clip and install the grommet that attach the rear LH ABS wheel speed sensor cable to the rear LH knuckle and bracket.
Caution:
Perform a push-pull check on the clip and grommet to make sure they are securely fastened to the knuckle and bracket.
22Connect the subframe harness to the rear LH ABS wheel speed sensor connector, and then fasten the clip that attaches the connector to the rear subframe.
23Repeat step 14 through 22 on the RH side of the rear drive unit.
24Fully raise the handle on the rear drive unit HV electrical harness.
25Attach the HV connector lever lock onto the back of the HV electrical harness.
26Firmly connect the HV electrical harness to the inverter connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
27While pressing the harness to the connector, remove the HV connector lever lock.
28While pressing the harness to the connector, fully lower the handle.
29Slide the release to lock the HV electrical harness.
30Install the bolt that attaches the HV harness bracket to the inverter.
Torque 6 Nm
31Connect the rear drive unit inlet hose to the inverter coolant inlet, and then fasten the clip.
Caution:
Perform a push-pull test to verify that the hose is fully seated.
32Fasten the clip that attaches the rear drive unit inlet hose to the HV harness bracket.
33Connect the electrical harness to the inverter low voltage connector.
34Fasten the clip that attaches the low voltage electrical harness to the inverter.
35Install the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).