Drive Unit - Rear - 3DU - Remove And Install: Install

Position the new rear drive unit beneath the gantry.
Attach the drive unit sling tool to the new rear drive unit.
Raise the new rear drive unit out of the crate.
Move the rear subframe and lifting tool beneath the rear drive unit.
With an assistant, lower the drive unit sling tool to install the new rear drive unit into the rear subframe.
Install and hand-tighten the bolt and nut that attach the rear bushing of the rear drive unit to the rear subframe.
Tip:

Use of the following tool(s) is recommended:
- 18 mm socket
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Install and hand-tighten the bolt that attaches the RH bushing of the rear drive unit to the rear subframe.
Tip:

Use of the following tool(s) is recommended:
- 18 mm socket
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Install and hand-tighten the bolt that attaches the LH bushing of the rear drive unit to the rear subframe.
NOTE:
Use of the following tool(s) is recommended:
- 18 mm socket
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Lower the drive unit sling tool to release the tension on the cables.
Remove the drive unit sling tool from the gantry.
Remove the drive unit sling tool from the rear drive unit.
Torque the LH, RH and rear motor mount bolts.
80 N.m (59.0 ft-lbs)

Tip:

Use of the following tool(s) is recommended:
- 18 mm socket
Remove the halfshaft plugs from the gearbox, and then with assistance, install the LH and RH rear drive unit halfshafts into the rear drive unit.
CAUTION: Take care not to damage or displace the oil seal.

CAUTION: Make sure that the opening of the snap ring is facing towards the bottom of the drive unit.

NOTE: Move the rear knuckle assembly aside to provide enough clearance to safely install the rear drive unit halfshaft.

NOTE: New rear 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.
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.
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Attach the clips that hold the coolant outlet hose to the rear drive unit.

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Install the coolant outlet hose to the rear drive unit cooler, and then attach the hose with a spring clip.
CAUTION: Perform a push-pull test to verify that the hose is fully seated.

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Install the inverter-to-cooler hose to the cooler, and then attach the hose with a spring clip.
CAUTION: Perform a push-pull test to verify that the hose is fully seated.

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Install the clips that attach the inverter-to-coolant hose to the rear drive unit.

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Install the inverter-to-cooler hose to the inverter, and then attach the hose with a spring clip.
CAUTION: Perform a push-pull test to verify that the hose is fully seated.

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Position the rear subframe and lifting tool beneath the rear drive unit.
Install the clips, and connect the electrical harness to the resolver connector.

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Connect the oil pump electrical connector, and then engage the connector lock.

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With an assistant, hand-tighten the bolt and nut that attach the LH rear 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 Rear Subframe Assembly (Remove and Install) procedure.

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With an assistant, hand-tighten the bolt and nut that attach LH rear 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 Rear Subframe Assembly (Remove and Install) procedure.

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With an assistant, hand-tighten the bolt and nut that attach the LH rear 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 Rear Subframe Assembly (Remove and Install) procedure.

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Loosely install the nut that attaches the LH rear lower fore link to LH rear knuckle

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Install the grommet that attaches the rear LH ABS wheel speed sensor cable to the rear LH knuckle.
CAUTION: Perform a push-pull check on the grommet to make sure it is securely fastened to the knuckle.

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Install the rear LH ABS wheel speed sensor to the knuckle, and then install a new bolt to attach the sensor to the knuckle.
5 N.m (3.7 ft-lbs)

Tip:

Use of the following tool(s) is recommended:
- 10 mm socket
- 6 in extension
Courtesy of TESLA, INC.
Fasten the clip that attaches the low voltage electrical harness to the inverter.

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Install the electrical harness clip, and then connect the electrical harness to the inverter low voltage connector.

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Install the bolt that attaches the ground strap harness to the rear drive unit.
6 N.m (4.4 ft-lbs)

Tip:

Use of the following tool(s) is recommended:
- 10 mm socket
- 4 in extension
Repeat step 23 through 28 on the RH side of the rear drive unit.
Position the rear drive unit HV cable on the rear subframe.
Fully raise the handle on the rear drive unit HV connector of the rear drive unit to HV battery harness.

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Install the HV connector special tool onto the rear drive unit HV connector.

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Use both hands to firmly connect the rear drive unit HV connector of the rear drive unit to HV battery harness to the rear drive unit HV header.
CAUTION: Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
Remove the HV connector special tool from the rear drive unit HV connector.
While pressing the rear drive unit HV connector onto the rear drive unit HV header, fully lower the handle.
CAUTION: Make sure that the handle does not bind as it is lowered.

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Slide the release to lock the rear drive unit HV connector handle in the secured position.

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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.
NOTE: An improperly seated connector might lead to connector damage and rear drive unit problems later on.
Install the bolt that attaches the HV harness bracket to the inverter.
6 N.m (4.4 ft-lbs)

Tip:

Use of the following tool(s) is recommended:
- 10 mm socket
Courtesy of TESLA, INC.
Connect the rear drive unit inlet hose to the inverter coolant coupling, and then fasten the spring clip.
CAUTION: Perform a push-pull test to verify that the hose is fully seated.

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Fasten the clip that attaches the rear drive unit inlet hose to the HV harness bracket.

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Install the rear subframe assembly. See SUBFRAME ASSEMBLY - REAR (3DU) (REMOVE AND INSTALL) .
Check the vehicle wheel alignment, and adjust if necessary. See FOUR WHEEL Alignment CHECK .