Inverter - Rear Drive Unit (Remove and Install)

Correction code 4020060140200601
  • 1130479-00-A Skt, 3/8in Dr, 10EP Torx Plus External

SPECIAL TOOLS

Skt, 3/8in Dr, 10EP Torx Plus External (1130479-00-A)
Caution:
This procedure must not be used for replacement of a defective inverter. For inverter replacement, see Inverter - Rear Drive Unit (Remove and Replace). Use this procedure to remove and install a functional inverter as part of another component's service operation. For example, the rear drive unit motor or gearbox.

Remove

  1. Remove the rear drive unit. See Drive Unit - Rear (Remove and Replace).
  2. Secure an ESD strap to the inverter housing.
  3. Remove the 3-phase access label.
  4. Remove the bolts (x2) that attach the 3-phase access cover to the rear drive unit.
  5. Remove and discard the 3-phase access cover.
  6. Remove and discard the bolts (x3) that attach the 3-phase terminals to the inverter assembly.
  7. Remove the bolts that attach the LH mount to the rear drive unit, and remove the mount from the rear drive unit.
  8. Remove and discard the bolts (x12) that attach the inverter to the gearbox assembly.
  9. Carefully remove the inverter assembly from the rear drive unit and allow the coolant to drain.
  10. Remove and discard the inverter gasket.
1Remove the rear drive unit. See Drive Unit - Rear (Remove and Replace).
2Secure an ESD strap to the inverter housing.
3Remove the 3-phase access label.
4Remove the bolts (x2) that attach the 3-phase access cover to the rear drive unit.
5Remove and discard the 3-phase access cover.
6Remove and discard the bolts (x3) that attach the 3-phase terminals to the inverter assembly.
7Remove the bolts that attach the LH mount to the rear drive unit, and remove the mount from the rear drive unit.
8Remove and discard the bolts (x12) that attach the inverter to the gearbox assembly.
9Carefully remove the inverter assembly from the rear drive unit and allow the coolant to drain.
10Remove and discard the inverter gasket.

Install

  1. Secure the ESD strap to the inverter housing.
  2. Carefully peel the gap pad from the inverter PCB.
  3. Use an IPA wipe to remove any residue and prepare the gap pad location on the inverter PCB.
  4. Peel the backing off of the new gap pad, position the pad into place, and press it onto the inverter PCB.
  5. Inspect the condition of the gap pad on the inverter PCB.
    • Fully covers the discharge resistor array and that no resistors are visible.
    • Clean and free of debris.
    • Evenly adhered to the inverter PCB.
  6. Install a new inverter gasket.
  7. Use an IPA wipe to clean the HV mating surfaces of the motor and inverter 3-phase terminals.
  8. Carefully align the inverter to the 2 pins in the rear drive unit, and then install the inverter to the rear drive unit. Make sure that the 3-phase terminals align during installation.
    Caution:
    Avoid damage to the printed circuit board of the inverter.
  9. Hand-tighten the new bolts (x12) that attach the inverter to the gearbox assembly.
  10. Torque the bolts in the sequence shown.
    Torque 5 Nm +20 deg
  11. Install the LH rear drive unit mount to the rear drive unit, and then hand-tighten the bolts (x3) that attach the mount to the rear drive unit.
  12. Tighten the bolts in a two-step, counter-clockwise pattern, starting with the upper-right bolt.
    Torque 35 Nm +55 deg
  13. Install the new bolts (x3) that attach the 3 phase cable to the inverter assembly.
    1. Tighten the bolts to this specification.
      Torque 11.5 Nm
    2. Loosen the bolts 180 degrees.
    3. Tighten the bolts to this specification.
      Torque 5 Nm +40 deg
  14. Apply a film of ATF-9 fluid to the walls of the gear case bores, and then install the new 3-phase access cover.
  15. Install the bolts (x2) that attach the 3-phase access cover to the rear drive unit assembly.
    Torque 7.5 Nm
  16. Perform an inverter air leak test. See Inverter Air Leak Test.
  17. Apply a new 3-phase access label.
  18. Remove the ESD wrist strap.
  19. Install the rear drive unit. See Drive Unit - Rear (Remove and Replace).
1Secure the ESD strap to the inverter housing.
2Carefully peel the gap pad from the inverter PCB.
3Use an IPA wipe to remove any residue and prepare the gap pad location on the inverter PCB.
4Peel the backing off of the new gap pad, position the pad into place, and press it onto the inverter PCB.
5Inspect the condition of the gap pad on the inverter PCB.
  • Fully covers the discharge resistor array and that no resistors are visible.
  • Clean and free of debris.
  • Evenly adhered to the inverter PCB.
6Install a new inverter gasket.
7Use an IPA wipe to clean the HV mating surfaces of the motor and inverter 3-phase terminals.
8Carefully align the inverter to the 2 pins in the rear drive unit, and then install the inverter to the rear drive unit. Make sure that the 3-phase terminals align during installation.
Caution:
Avoid damage to the printed circuit board of the inverter.
9Hand-tighten the new bolts (x12) that attach the inverter to the gearbox assembly.
10Torque the bolts in the sequence shown.
Torque 5 Nm +20 deg
11Install the LH rear drive unit mount to the rear drive unit, and then hand-tighten the bolts (x3) that attach the mount to the rear drive unit.
12Tighten the bolts in a two-step, counter-clockwise pattern, starting with the upper-right bolt.
Torque 35 Nm +55 deg
13Install the new bolts (x3) that attach the 3 phase cable to the inverter assembly.
  1. Tighten the bolts to this specification.
    Torque 11.5 Nm
  2. Loosen the bolts 180 degrees.
  3. Tighten the bolts to this specification.
    Torque 5 Nm +40 deg
14Apply a film of ATF-9 fluid to the walls of the gear case bores, and then install the new 3-phase access cover.
15Install the bolts (x2) that attach the 3-phase access cover to the rear drive unit assembly.
Torque 7.5 Nm
16Perform an inverter air leak test. See Inverter Air Leak Test.
17Apply a new 3-phase access label.
18Remove the ESD wrist strap.
19Install the rear drive unit. See Drive Unit - Rear (Remove and Replace).