04/11/2024 04:57:45

Halfshaft - Front Drive Unit - RH (2nd Generation) (Remove and Replace)

Correction Code 39303202

This procedure is for vehicles built after April 24, 2019. For vehicles built through April 24, 2019, See .

  • 2023-12-14: Added step to perform test drive to break in new halfshaft(s).

Removal

  1. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Remove the RH front wheel. See Wheel Assembly (Remove and Install).
  3. Remove the front aero shield panel. See .
  4. Remove and discard the RH nyloc nut that attaches the tie rod end to the steering knuckle, and then disconnect the tie rod from the steering knuckle.
  5. Remove and discard the nut that attaches the RH stabilizer bar to the stabilizer bar end link, and then remove the end link from the stabilizer bar.
    Figure 1. LH shown, RH similar
  6. Release the grommets (x2) and clip that attach the RH wheel speed sensor to the knuckle, and then set the sensor aside.
    Figure 2. LH shown; RH similar
  7. Remove and discard the bolt and nut that attach the upper control arm ball joint to the knuckle.
  8. (1626638-00-A and newer only): Remove the bolt and nut that attach the bottom of the RH front air spring module to the RH front lower control arm.
    Informational PurposesAn informational icon, calling your attention
    Note
    This step is only necessary for halfshaft 1626638-00-A and newer. These halfshafts have a larger CV housing that require more room for access.
    Figure 3. LH shown; RH similar
  9. Remove the nut and discard the washer that attach the RH front halfshaft to the hub.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut can be reused.
  10. Install the hydraulic hub puller on the RH hub assembly using 2 lug nuts and 2 hydraulic hub puller washers.
  11. Separate the RH halfshaft from the hub splines using the hydraulic hub puller, and then remove the puller from the hub.
  12. With assistance, remove the halfshaft from the hub.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    To reduce the risk of personal injury, wear cut resistant gloves and proper personal protective equipment (PPE) as required when removing the halfshaft. Keep hands clear from other components to prevent injury when the halfshaft releases from the Drive Unit.
  13. Install the axle removal tool around the inner joint of the RH front halfshaft.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a cable tie to secure the axle removal tool in place.
    Figure 4. Close-up view of axle removal tool on halfshaft
  14. Remove the halfshaft from the front drive unit using the axle removal tool, and then remove the halfshaft from the vehicle.

Installation

  1. Install the halfshaft into the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    • When installing the halfshaft(s) into the drive unit:
      • Make sure that the opening of the snap ring is facing towards the bottom of the drive unit.
      • Do not damage or displace the oil seal.
      • Verify that the halfshaft is 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.
  2. Apply no more than 1 gram of Molykote M-77 lubricant paste only to the hub mating face on the outboard side of the halfshaft.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply any lubricant to the halfshaft splines. If lubricant is mistakenly applied, wipe the splines clean with a shop towel.
  3. Align the splines of the RH front halfshaft with those of the RH front hub, and then install the halfshaft into the hub.
  4. Install only the axle nut onto the halfshaft, and then use a ratchet and socket to manually tighten the nut to pull the halfshaft into the hub until it seats.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not use power tools to tighten the nut as it might strip the threads.
  5. Remove the axle nut from the halfshaft, install a new washer onto the halfshaft, and then reinstall the axle nut hand tightened.
    Informational PurposesAn informational icon, calling your attention
    Note
    The axle nut is torqued in a later step.
  6. Connect the RH front upper control arm to the knuckle.
  7. Install a new bolt and nut that attach the knuckle to the upper control arm ball joint (torque 60 Nm).
  8. Install new nut that attaches the stabilizer bar to the stabilizer bar end links (torque 70 Nm).
  9. Restrain the tie rod ball joint pin, and then install a new nut that attaches the RH tie rod end to the knuckle (torque 103 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    To prevent ball joint damage, always hold the ball joint pin with a wrench while tightening the lock nut.
  10. (1626638-00-A and newer only): Move the RH front air spring module into position, and then hand-tighten the bolt and nut that attach the air spring module to the RH front lower control arm.
    Informational PurposesAn informational icon, calling your attention
    Note
    This step is only necessary for halfshaft 1626638-00-A and newer. These halfshafts have a larger CV housing that require more room for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    This joint is torqued in a later step.
    Figure 5. LH shown; RH similar
  11. Install the grommets (x2) and clip that attach the RH wheel speed sensor to the knuckle.
    Figure 6. LH shown; RH similar
  12. Install the front aero shield panel. See .
  13. Install the RH front wheel, but do not install the wheel center cap at this time See Wheel Assembly (Remove and Install).
  14. Tighten the RH front axle nut (torque 245 Nm).
  15. Install the RH front wheel center cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the emblem is aligned with the valve stem.
  16. Lower the vehicle, and then remove the vehicle from the lift.
  17. Halfshafts 1626638-00-A and newer only:
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform the following steps only if the front air spring to front lower control arm joint was loosened.
    1. Move the vehicle to a 4-post lift.
    2. Torque the bolt that attaches the RH front air spring module to the RH front lower control arm (torque 140 Nm). Mark the nut with a paint pen.
    3. Remove the vehicle from the 4-post lift.
  18. Perform a test drive to break in the new halfshaft(s).
    Informational PurposesAn informational icon, calling your attention
    Note
    Add correction code 00040100 as a separate activity to the Service Visit.
    1. Make sure that the HV battery SOC is above 70%. Charge the HV battery as necessary.
    2. On the vehicle touchscreen, select Standard or Sport for Acceleration.
    3. Perform a full-throttle acceleration from 0 - 80 kph (0 - 50 mph) for 3 times. Confirm absence of excessive vibrations or shuddering at the front of the vehicle.
      Informational PurposesAn informational icon, calling your attention
      Note
      If vibration or shuddering is noticed, refer to SB-21-39-001 - Replace Front Drive Unit Halfshafts.