41 00... Check Of Drive Module (Aluminium)

The Drive module consists of extruded profiles and cast parts in aluminium.

Cast part are used as spring strut dome and as rear axle module. Any other components are extruded profiles.

Check for damage (deformation) using a straightening system or beam trammel.

For optical testing, strip adjoining components in cases of doubt.

Extruded profiles and cast parts showing visible or measurable signs of deformation must be replaced.

The relative component must be replaced when showing sharp-edged damages or cracks.

Example rear axle module:

The rear axle module must be replaced if the bearing support of the rubber mount is broken.

Exceptions apply for the following components: 

1. Screw connection of deformation element, front.

   The side member is deformed when attaching the deformation element to the side member (1) by means of screws.

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   maximum depth of 1 mm are permitted along the line (2).

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2. Screw connection of deformation element, rear.

   Pressure marks in areas (1) caused by the thread of the screwed connections of the deformation elements are permitted.

   When there is damage to the deformation element, the rear axle module must be replaced only if the specified values are exceeded.

   Dimension bearing stress a =2 mm.

   NOTE: Screw connection hole (2) dia. 14 mm.

   Screw connection hole (3) elongated hole 16x14 mm.

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3. Connection of tension struts on left and right (1) to rear end strut (2)

   When there is deformation of the rear end strut in areas (3) in the longitudinal direction of the vehicle (x-direction), the rear end strut must be replaced only if the specified values are exceeded.

   Dimension (A) = 2 mm.

   If there are cracks, the rear end strut (2) must be replaced.

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4. Holder, cooling package (1)

   If deformed, the holder (1) can be straightened. After straightening, visually inspect the welded seam (2) for cracks.

   If the welded seam is cracked, the SIDE MEMBER  must be replaced.

5. Bridge (1) on the Drive module in the area of the high-voltage battery

   The purpose of the bridge (1) is to protect the screws (2) from damage.

   For damage up to 5 mm deep, deburr the damaged area and paint.

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   If necessary, replace the damaged screws (2) of the high-voltage battery.

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6. U section (1) on the cross member

   The purpose of the U section (1) is to protect the screw from damage.

   For damage up to 2 mm deep, deburr the damaged area and paint.

   For damage deeper than 2 mm, the cross member must be replaced.

   Replace damaged screw, if necessary.

The seat cross members cannot be replaced separately. In the case of damaged seat cross members, the bodyshell must be replaced.

Reshaping or heating extruded profiles and cast parts is not permitted! 

Failure to comply with this requirement would have the following results:

• In the case of reshaping, weld seams tear in the surrounding area.
• In the case of reshaping, the material loses up to 40 % of its original strength.
• In the case of heating, the material loses up to 40 % of its original strength.

Take the gap dimensions for doors, engine compartment lid and tailgate from the gap dimension diagram shown in the individual repair instructions.