- Inspect the tires for abnormal wear.
NOTE:
Note any abnormal tire wear that could indicate the need for an alignment.
- Raise and support vehicle.
NOTE:
Ensure vehicle is not charging.
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- Open all four doors.
NOTE:
If vehicle is being powered down, Latch rear doors to prevent accidental closure.
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- Lower all four windows.
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- Move LH front seat forward.
- Move RH front seat forward.
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- Place vehicle in service mode through UI.
NOTE:
Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box.
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- Unlock vehicle gateway.
NOTE:
After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information.
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- Run Thermal Fill Drain (Coolant Only) through the UI.
NOTE:
Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again.
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- Place vehicle into tow mode.
NOTE:
Via Controls > Service > "Towing".
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- Open hood.
- Remove rear underhood apron.
NOTE:
14x clips.
- Power off vehicle from center display.
NOTE:
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box.
- Disconnect LV battery and First Responder Loop.
NOTE:
2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge.
- Release 2nd row seat cushion and disconnect harness.
NOTE:
2x clips, 2x connectors, Press tabs backward then pull front edge up.
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- Verify operation of multimeter.
NOTE:
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery.
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- Remove all items from pockets and ensure not wearing metal items.
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- Inspect HV insulating gloves.
NOTE:
Check gloves for damage prior to use, refer to Tech Note TN-15-92-003
, for information on inspecting HV gloves.
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- Put on HV insulating gloves and leather over gloves.
NOTE:
Make sure to wear Electrical Protective Gloves any time Hioki tester is used.
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- Remove bolts securing ancillary bay probe lid cover to ancillary bay cover.
NOTE:
2x bolts, EP10 5-Lobe, 6 N.m, Discard after removal.
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- Remove ancillary bay probe lid cover from ancillary bay cover.
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- Verify no high voltage.
NOTE:
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering.
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- Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover.
NOTE:
Confirm no visual damage present, Wipe ancillary bay with IPA to clean surface, Allow to 1 minute dry time.
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- Install bolts securing ancillary bay probe lid cover to ancillary bay cover.
NOTE:
2x bolts, E10 5-Lobe, 6 N.m, Install new fasteners.
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- Remove HV insulating gloves.
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- Remove LH rear wheel center cap.
NOTE:
1x cap.
- Loosen LH rear wheel.
NOTE:
5x nuts, 21 mm, 175 N.m.
- Remove RH rear wheel center cap.
NOTE:
1x cap.
- Loosen RH rear wheel.
NOTE:
5x nuts, 21 mm, 175 N.m.
- Raise vehicle partially and lower lift onto locks.
NOTE:
Set vehicle to a comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
- Remove LH rear wheel.
NOTE:
5x nuts, 21 mm, 175 N.m.
- Remove RH rear wheel.
NOTE:
5x nuts, 21 mm, 175 N.m.
- Open trunk from exterior switch.
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- Remove LH trough trim.
NOTE:
3x clips, 1x bolt, T20, 1.2 N.m.
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- Remove RH trough trim.
NOTE:
3x clips, 1x bolt, T20, 1.2 N.m.
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- Remove bolt securing LH corner of rear fascia to body.
NOTE:
1x bolt, 10 mm, 4 N.m.
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- Remove bolt securing RH corner of rear fascia to body.
NOTE:
1x bolt, 10 mm, 4 N.m.
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- Raise vehicle fully and lower lift onto locks.
NOTE:
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects.
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- Remove LH and RH clips securing rear aero shield to wheel house liner.
NOTE:
2x clips.
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- Remove rear aero shield.
NOTE:
11x bolts, 10 mm, 5 N.m.
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- Remove LH rear suspension cover.
NOTE:
1x bolt, 10 mm, 6 N.m, 2x tabs.
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- Remove RH rear suspension cover.
NOTE:
1x bolt, 10 mm, 6 N.m, 2x tabs.
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- Remove lower clips securing LH rear wheel liner.
NOTE:
3x push clips.
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- Remove lower clips securing RH rear wheel liner.
NOTE:
3x push clips.
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- Remove bolts securing the rear diffuser to body.
NOTE:
4x bolts, 10 mm, 4 N.m, 2x fastener covers.
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- Lower vehicle partially and set lift onto locks.
NOTE:
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
- Remove screw securing rear fascia to LH quarter panel.
NOTE:
1x screw, T25, 2 N.m.
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- Remove screw securing rear fascia to RH quarter panel.
NOTE:
1x screw, T25, 2 N.m.
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- Remove rear fascia and place on padded surface.
NOTE:
2x connector, Recommend assistance.
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- Remove LH rear brake caliper from knuckle and hang from body.
NOTE:
2x bolts, E18, 83 N.m, Discard after removal, Hand tighten lug nut to secure rotor on early production vehicles.
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- Install spring compressor onto LH rear coil spring.
NOTE:
Tooling may vary per service center, Reference photos for clarification.
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- Unbolt LH damper from body at top mount.
NOTE:
2x bolts, 15 mm, 41 N.m.
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- Remove RH rear brake caliper from knuckle and hang from body.
NOTE:
2x bolt, E18, 83 N.m, Discard bolts after removal, Hand tighten lug nut to secure rotor on early production vehicles.
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- Install spring compressor onto RH rear coil spring.
NOTE:
Tooling may vary per service center, Reference photos for clarification.
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- Unbolt RH damper from body at top mount.
NOTE:
2x bolts, 15 mm, 41 N.m.
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- Remove nut securing RDU ground strap to vehicle.
NOTE:
1x nut, 10 mm, 10 N.m, Located at LH rear wheel well area.
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- Raise vehicle fully and lower lift onto locks.
NOTE:
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects.
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- Disconnect RH side subframe harness connector.
NOTE:
1x connector, Release locking tab.
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- Remove RH side subframe harness clip from body.
NOTE:
1x barrel clip.
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- Remove nut securing LH rear stabilizer bar end link to stabilizer bar.
NOTE:
1x nyloc nut, 15 mm, 55 N.m, Break nut loose then counter-hold ball joint with 5 mm hex, Discard after removal.
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- Remove stabilizer bar from LH rear end link.
NOTE:
May need to move the stabilizer bar up/down to get the correct angle to remove end link.
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- Remove nut securing RH rear stabilizer bar end link to stabilizer bar.
NOTE:
1x nyloc nut, 15 mm, 55 N.m, Break nut loose then counter-hold ball joint with 5 mm hex, Discard after removal.
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- Remove stabilizer bar from RH rear end link.
NOTE:
May need to move the stabilizer bar up/down to get the correct angle to remove end link.
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- Remove bolts securing rear stabilizer bar to subframe and remove assembly.
NOTE:
4x patch bolts, 11 mm, 30 N.m, Discard after removal.
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- Release clips securing coolant hoses to LH shear plate.
NOTE:
2x fir tree clips.
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- Release LH side hose clip from rear battery skid plate enclosure.
NOTE:
1x fir tree clip.
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- Release RH side hose clips from rear battery skid plate enclosure.
NOTE:
2x fir tree clips.
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- Release clips securing coolant hoses to RH shear plate.
NOTE:
2x fir tree clips.
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- Remove lower bolts securing HV battery rear skid plate enclosure.
NOTE:
2x bolts, EP10, 13 N.m, Older vins may be equipped with additional fastener count.
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- Remove upper nut securing HV battery rear skid plate enclosure.
NOTE:
1x nut, 10 mm, 13 N.m, Fastener count may vary on older built vehicles.
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- Remove upper bolts securing HV battery rear skid plate enclosure.
NOTE:
4x bolts, 13 mm, 35 N.m.
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- Remove HV battery rear skid plate enclosure.
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- Position coolant drain container underneath LH rear of HV battery.
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- Disconnect RDU inverter inlet tube from LH rear of HV battery.
NOTE:
1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill.
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- Position coolant drain container underneath RH rear of vehicle.
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- Release push clips securing RH rear wheel liner to rocker panel.
NOTE:
2x clips, Remove indicated clips and move liner aside for access.
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- Disconnect RDU outlet hose from PT return tube and plug both hose ends.
NOTE:
1x spring clip, 2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary, Coolant loss greater than 1 L will require vacuum fill.
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- Position coolant drain container underneath LH RDU area.
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- Disconnect RDU inverter inlet tube from fluid coupling.
NOTE:
1x spring clip, 2x plugs, Plug the hose end and the fluid coupling.
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- Release RDU inverter inlet tube from RDU HV cable harness.
NOTE:
1x fir tree clip.
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- Remove RDU inverter inlet hose from subframe.
NOTE:
Maneuver hose as needed to remove from between rear subframe and RDU HV cable harness, Remove plugs from both ends and allow coolant to fully drain if discarding.
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- Remove coolant drain container from underneath vehicle.
- Remove bolt securing RDU HV cable bracket to RDU.
NOTE:
1x bolt, 10 mm, 6 N.m.
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- Remove nut securing RDU HV cable bracket to HV battery.
NOTE:
1x nut, 10 mm, 10 N.m.
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- Disconnect RDU HV cable from HV battery.
NOTE:
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged.
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- Release RDU HV harness connection.
NOTE:
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged.
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- Remove RDU HV harness.
NOTE:
Rotate and route cable between subframe, rear drive unit and battery.
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- Place subframe lifting tool into position underneath rear subframe.
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- Connect air supply to subframe lifting tool.
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- Raise subframe lifting tool to support rear subframe.
NOTE:
3x straps, Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure, Lower the vehicle if necessary, Recommend assistance.
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- Mark LH rear and RH rear subframe bolts.
NOTE:
2x bolts, Mark original location of subframe, Re-align during install, Can also mark subframe casting and subframe bushing to body if needed.
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- Remove smaller fasteners securing LH shear plate.
NOTE:
2x bolts, 13 mm, 35 N.m.
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- Remove large bolt securing LH shear plate and subframe to body and remove shear plate.
NOTE:
1x bolt, 21 mm, 130 N.m, Discard after removal.
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- Remove smaller fasteners for RH shear plate.
NOTE:
2x bolts, 13 mm, 35 N.m.
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- Remove large bolt securing RH shear plate and subframe to body and remove shear plate.
NOTE:
1x bolt, 21 mm, 130 N.m, Discard after removal.
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- Remove LH rear bolt securing subframe to body.
NOTE:
1x bolt, 21 mm, 165 N.m, Discard after removal.
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- Remove RH rear bolt securing subframe to body.
NOTE:
1x bolt, 21 mm, 165 N.m, Discard after removal.
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- Lower subframe and rear drive unit assembly from vehicle.
NOTE:
Use caution while lowering subframe to avoid damage to surrounding components.
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- Disconnect air supply from subframe lifting tool.
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- Move the subframe lifting tool and subframe away from vehicle.
NOTE:
Raise vehicle if necessary.
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- Release RDU ground strap clip from subframe.
NOTE:
1x clip.
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- Remove ground strap harness from RDU assembly.
NOTE:
1x bolt, 10 mm, 6 N.m.
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- Position fluid catcher under subframe and fixture assembly.
NOTE:
Position to catch all coolant loss, Use a foldable funnel as required for the next steps.
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- Release RDU inverter to oil cooler hose.
NOTE:
1x hose clip, Image zoomed in for clarity.
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- Release RDU inverter coolant hose from heat exchanger.
NOTE:
1x hose clip, Use a foldable funnel as required.
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- Release clips securing RDU inverter to oil cooler hose and remove hose.
NOTE:
4x clips.
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- Release coolant outlet hose from RDU heat exchanger and plug both ends.
NOTE:
1x spring clip, 2x plugs, Use shop towel to clean any residue coolant if necessary, Coolant loss greater than 1 L will require vacuum fill.
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- Release clips securing coolant outlet hose to RDU and remove hose.
NOTE:
4x clips.
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- Release RDU logic connection clip.
NOTE:
1x clip.
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- Release RDU logic connection.
NOTE:
1x connector, Release locking tab then push the handle downward to release connector.
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- Disconnect resolver connector.
NOTE:
1x connector.
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- Release clips from rear drive unit.
NOTE:
2x clips.
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- Disconnect oil pump connector.
NOTE:
1x connector.
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- Remove bolt securing LH rear wheel speed sensor to knuckle.
NOTE:
1x bolt, 10 mm, 5 N.m.
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- Remove grommet securing LH rear wheel speed sensor to knuckle.
NOTE:
1x grommet.
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- Remove nut and bolt securing LH rear upper aft link to knuckle.
NOTE:
1x bolt, 1x nut, 21 mm, 134 N.m.
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- Remove nut and bolt securing LH rear upper fore link to knuckle.
NOTE:
1x nut, 18 mm, 76 N.m.
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- Remove nut and bolt securing LH rear toe link to knuckle.
NOTE:
1x bolt, 1x nut, 18 mm, 76 N.m.
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- Loosen nut and bolt securing LH rear lower fore link to knuckle, but do not remove fastener.
NOTE:
1x bolt, 1x nut, 18 mm, 76 N.m, Loosen fastener to allow further pivoting, Fastener does not need to be removed.
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- Separate LH half shaft from RDU using the cable removal kit.
NOTE:
1x U-bolt, 2x nuts, 10 mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing, Remove cable when done.
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- Remove bolt securing RH wheel speed sensor to knuckle.
NOTE:
1x bolt, 10 mm, 5 N.m.
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- Remove grommet securing RH wheel speed sensor to knuckle.
NOTE:
1x grommet.
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- Remove nut and bolt securing RH rear upper aft link to knuckle.
NOTE:
1x bolt, 1x nut, 21 mm, 134 N.m.
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- Remove nut and bolt securing RH rear upper fore link to knuckle.
NOTE:
1x bolt, 1x nut, 18 mm, 76 N.m.
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- Remove nut and bolt securing RH rear toe link to knuckle.
NOTE:
1x bolt, 1x nut, 18 mm, 76 N.m.
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- Loosen nut and bolt securing RH rear lower fore link to knuckle, but do not remove fastener.
NOTE:
1x bolt, 1x nut, 18 mm, 76 N.m, Loosen fastener to allow further pivoting, Fastener does not need to be removed.
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- Separate RH half shaft from RDU using the cable removal kit.
NOTE:
1x U-bolt, 2x nuts, 10 mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing, Remove cable when done.
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- Position the rear subframe assembly under gantry.
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- Attach drive unit sling tool to drive unit.
NOTE:
3x hooks.
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- Secure drive unit sling to gantry.
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- Raise sling so there is slight tension on the cables.
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- Remove LH bolt securing drive unit to subframe.
NOTE:
1x bolt, 18 mm, 80 N.m.
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- Remove RH bolt securing drive unit to subframe.
NOTE:
1x bolt, 18 mm, 80 N.m.
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- Remove bolt securing rear of drive unit to subframe.
NOTE:
1x bolt, 18 mm, 80 N.m.
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- Raise sling to lift drive unit out of subframe.
NOTE:
Carefully lift drive unit out of subframe, As the RDU is lifted maneuver the half shafts out of the way.
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- Move subframe and lifting tool from underneath drive unit.
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- Position empty drive unit crate below M3 drive unit.
NOTE:
Use pallet if no empty crate available.
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- Lower drive unit into drive unit crate.
NOTE:
Use pallet if no empty crate available.
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- Remove drive unit sling from gantry.
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- Remove drive unit sling tool from the removed drive unit.
NOTE:
3x hooks.
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