Bushing - Gearbox - Front Drive Unit (Remove and Replace)

Correction code 3901120239011202
  • 1053595-00-AEngine Motor Stand, 1000 lb. (NA, APAC)
  • 1053595-01-AEngine Stand, 1000 lbs (EMEA)
  • 1467557-00-AFixture, DUF Disassembly, Model 3
  • 1133386-00-ATool, Axle Extraction, Model 3
  • 1137785-00-AKit, Drive Unit Bushing R&R, Model 3

SPECIAL TOOLS

Engine Motor Stand, 1000 lb. (NA, APAC) (1053595-00-A)
Engine Stand, 1000 lbs (EMEA) (1053595-01-A)
Fixture, DUF Disassembly, Model 3 (1467557-00-A)
Tool, Axle Extraction, Model 3 (1133386-00-A)
Kit, Drive Unit Bushing R&R, Model 3 (1137785-00-A)

Remove

  1. Remove the front subframe assembly from the vehicle. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
  2. Remove the steering rack. See Steering Rack (RWD) (Remove and Replace).
  3. Install an axle extraction tool between the front drive unit and the inner joint of the LH front drive unit halfshaft, and then strike the handle end of the extraction tool with a dead blow hammer to unseat the halfshaft.
  4. With assistance, remove the LH front drive unit halfshaft from the front drive unit, and then install a halfshaft plug into the opening of the gearbox.
  5. Repeat steps 3 to 4 on the RH front drive unit halfshaft.
  6. Release the locking tab, and then push the handle downward to disconnect the front drive unit inverter logic connector.
  7. Release the red locking tab, and then press down on the tab to disconnect the resolver logic connector.
  8. Release the grey locking tab, and then press down on the tab to disconnect the oil pump connector.
  9. Release the clip that attaches the front drive unit harness to the front drive unit motor.
  10. Release the clips that attach the front drive unit harness to the front drive unit inverter.
  11. Position the subframe assembly under the gantry.
  12. Position the front drive unit engine stand adapter on the front drive unit, and then hand-tighten the bolts that attach the engine stand adapter to the front drive unit.
    Other assemblies hidden for clarity
  13. Attach the gantry hook to the front drive unit engine stand adapter, as shown.
    Other assemblies hidden for clarity
  14. Raise the gantry hook until it is taut.
  15. Remove the bolt that attaches the front drive unit to the front subframe.
  16. Lift the front drive unit up and away from the front subframe.
    Note: Make sure not to move the rear front drive unit support posts.
  17. Position the front drive unit engine stand adapter on the engine stand, and then hand-tighten the bolts that attach the engine stand adapter to the engine stand.
  18. Remove the gantry hook from the engine stand adapter.
  19. Install the bushing tool on the front drive unit gearbox bushing.
    Note: Use cups "K", "A", "H", and "L" when assembling the special tool, as shown.
  20. Turn the bearing-side bushing tool nut with a wrench while holding the opposite nut in place.
  21. When the bushing has been pushed out of the front drive unit gearbox, separate the bushing tool, and then remove the bushing.
1Remove the front subframe assembly from the vehicle. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
2Remove the steering rack. See Steering Rack (RWD) (Remove and Replace).
3Install an axle extraction tool between the front drive unit and the inner joint of the LH front drive unit halfshaft, and then strike the handle end of the extraction tool with a dead blow hammer to unseat the halfshaft.
4With assistance, remove the LH front drive unit halfshaft from the front drive unit, and then install a halfshaft plug into the opening of the gearbox.
5Repeat steps 3 to 4 on the RH front drive unit halfshaft.
6Release the locking tab, and then push the handle downward to disconnect the front drive unit inverter logic connector.
7Release the red locking tab, and then press down on the tab to disconnect the resolver logic connector.
8Release the grey locking tab, and then press down on the tab to disconnect the oil pump connector.
9Release the clip that attaches the front drive unit harness to the front drive unit motor.
10Release the clips that attach the front drive unit harness to the front drive unit inverter.
11Position the subframe assembly under the gantry.
Other assemblies hidden for clarity
12Position the front drive unit engine stand adapter on the front drive unit, and then hand-tighten the bolts that attach the engine stand adapter to the front drive unit.
Other assemblies hidden for clarity
13Attach the gantry hook to the front drive unit engine stand adapter, as shown.
14Raise the gantry hook until it is taut.
15Remove the bolt that attaches the front drive unit to the front subframe.
16Lift the front drive unit up and away from the front subframe.
Note: Make sure not to move the rear front drive unit support posts.
17Position the front drive unit engine stand adapter on the engine stand, and then hand-tighten the bolts that attach the engine stand adapter to the engine stand.
18Remove the gantry hook from the engine stand adapter.
19Install the bushing tool on the front drive unit gearbox bushing.
Note: Use cups "K", "A", "H", and "L" when assembling the special tool, as shown.
20Turn the bearing-side bushing tool nut with a wrench while holding the opposite nut in place.
21When the bushing has been pushed out of the front drive unit gearbox, separate the bushing tool, and then remove the bushing.

Install

  1. Set up the bushing tool to press in the new bushing.
    Note: Use cups "L", "H", and "D" when assembling the special tool, as shown.
  2. Turn the bearing-side bushing tool nut with a wrench until the bushing is fully installed.
  3. Separate the bushing tool, and then remove it from the drive unit.
  4. Attach the gantry hook to the front drive unit engine stand adapter, as shown.
  5. Raise the gantry hook until it is taut.
  6. Remove the bolts that attach the front drive unit engine stand adapter to the engine stand, and then set the engine stand aside.
  7. Position the front drive unit over the front subframe, and then lower the front drive unit onto the front subframe.
    Note: Make sure not to move the rear front drive unit support posts from their previous positions.
  8. Install the bolt that attaches the front drive unit to the front subframe.
    Torque 80 Nm
  9. Lower the gantry hook until the gantry hook is slack.
  10. Remove the bolts that attach the front drive unit engine stand adapter to the front drive unit, and then set the engine stand adapter aside.
  11. Move the subframe lifting tool to a working area.
  12. Install the clips that attach the front drive unit harness to the front drive unit inverter.
  13. Install the clip that attaches the front drive unit harness to the front drive unit motor.
  14. Connect the oil pump connector, and then engage the locking tab.
    Important: Perform a push-pull test to verify that the connector is fully attached.
  15. Connect the resolver logic connector, and then engage the locking tab.
    Important: Perform a push-pull test to verify that the connector is fully attached.
  16. Connect the front drive unit inverter logic connector, close the handle, and then engage the locking tab.
    Important: Perform a push-pull test to verify that the connector is fully attached.
  17. Apply approximately 1 gram of Molykote M-77 Lubricant Paste only to the hub mating face on the outboard side of the LH and RH front drive unit halfshafts.
    Caution:
    Do not apply any lubricant to the halfshaft splines. If lubricant is mistakenly applied, wipe the splines clean with a shop towel.
  18. Remove the halfshaft plugs from the gearbox, and then with assistance, install the LH and RH front drive unit halfshafts into the front drive unit.
    Note: Move the LH and RH front knuckle assemblies aside to provide enough clearance to safely install the LH and RH front drive unit halfshafts.
  19. Install the steering rack. See Steering Rack (RWD) (Remove and Replace).
  20. Install the front subframe assembly on the vehicle. See Subframe Assembly - Front (Dual Motor) (Remove and Install).
1Set up the bushing tool to press in the new bushing.
Note: Use cups "L", "H", and "D" when assembling the special tool, as shown.
2Turn the bearing-side bushing tool nut with a wrench until the bushing is fully installed.
3Separate the bushing tool, and then remove it from the drive unit.
4Attach the gantry hook to the front drive unit engine stand adapter, as shown.
5Raise the gantry hook until it is taut.
6Remove the bolts that attach the front drive unit engine stand adapter to the engine stand, and then set the engine stand aside.
7Position the front drive unit over the front subframe, and then lower the front drive unit onto the front subframe.
Note: Make sure not to move the rear front drive unit support posts from their previous positions.
8Install the bolt that attaches the front drive unit to the front subframe.
Torque 80 Nm
9Lower the gantry hook until the gantry hook is slack.
10Remove the bolts that attach the front drive unit engine stand adapter to the front drive unit, and then set the engine stand adapter aside.
11Move the subframe lifting tool to a working area.
12Install the clips that attach the front drive unit harness to the front drive unit inverter.
13Install the clip that attaches the front drive unit harness to the front drive unit motor.
14Connect the oil pump connector, and then engage the locking tab.
Important: Perform a push-pull test to verify that the connector is fully attached.
15Connect the resolver logic connector, and then engage the locking tab.
Important: Perform a push-pull test to verify that the connector is fully attached.
16Connect the front drive unit inverter logic connector, close the handle, and then engage the locking tab.
Important: Perform a push-pull test to verify that the connector is fully attached.
17Apply approximately 1 gram of Molykote M-77 Lubricant Paste only to the hub mating face on the outboard side of the LH and RH front drive unit halfshafts.
Caution:
Do not apply any lubricant to the halfshaft splines. If lubricant is mistakenly applied, wipe the splines clean with a shop towel.
18Remove the halfshaft plugs from the gearbox, and then with assistance, install the LH and RH front drive unit halfshafts into the front drive unit.
Note: Move the LH and RH front knuckle assemblies aside to provide enough clearance to safely install the LH and RH front drive unit halfshafts.
19Install the steering rack. See Steering Rack (RWD) (Remove and Replace).
20Install the front subframe assembly on the vehicle. See Subframe Assembly - Front (Dual Motor) (Remove and Install).