Rear Axle Module Replacement Rep-Rep-RAI0141-4111435 - V.10

Special tools required:

2 355 218
2 355 732

WARNING: High-voltage system - mortal hazard
Compliance with the following points is mandatory before beginning work:

De-energize the HIGH-VOLTAGE SYSTEM .
Observe SAFETY INSTRUCTIONS for working with electric vehicles.

The following body parts are required (see Electronic Parts Catalog EPC):

Rear axle module
Outside reinforcement plate on drive module (quantity: 2)
Inside reinforcement plate on drive module (quantity: 2)

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Washer (quantity: 4 part number 31 10 6 779 382)

Following CONSUMABLES are required:

Material	Quantity
Adhesive K1	1
Adhesive K2	2
Cleaning agent R1	1
Blind rivet N1	70
EMC screws	16
Non-woven abrasives S1
Sealant D1	1
Spray can, black, matte	1

NOTE: Observe (REPAIR STAGE 2) procedure!

Preliminary work needed:

Remove HIGH-VOLTAGE BATTERY UNIT .

Insert special tool 2 355 218 on both sides of vehicle at rear on side frame and lock.

Lift car at rear using special tool 2 355 218 .

WARNING: Car may slip off the vehicle hoist if the weight is distributed unevenly.
Load the trunk of the vehicle before disassembly down or secure it with a tensioning strap (1).

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The tensioning force of the tensioning strap must be equal to or greater than 2000 daN (2 t).

Strip down vehicle.

Removal

In area (1), the rear axle module is bonded to the life module.

Place cutting wire (2) around the adhesive bead (1) (pull downwards at an angle).

Attention!

Risk of damage!

Do not touch Carbon Fiber Reinforced Plastic parts with the cutting wire.

Disconnect the adhesive bead using WIRE HANDLES .

Repeat operation on right side of vehicle.

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In areas (1) and (4), jacking point (2) is bonded with the life module.

Place cutting wire (2) around the adhesive bead (1) (pull horizontally toward the rear).

Attention!

Risk of damage!

Do not touch Carbon Fiber Reinforced Plastic parts with the cutting wire.

Disconnect the adhesive bead using WIRE HANDLES .

Sever adhesive bead (4) in the same manner.

Repeat operation on right side of vehicle.

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View from rear:

Attention!

Risk of damage!

Saw blade must not touch Carbon Fiber Reinforced Plastic parts.

Second person needed for CHECKING AND PROTECTION of non-visible areas.

Cut adhesive bead (1) with reciprocating saw.

NOTE: A centering pin (2) is located in the center of the vehicle that needs to be sawed through.

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View from inside/below:

Attention!

Risk of damage!

Second person needed for CHECKING AND PROTECTION of non-visible areas.

Mark severance cut in accordance with Dimension a and cut.

Dimension (A) = 500 mm.

Repeat operation on right side of vehicle.

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View from outside

WARNING: Injury hazard!
A suitable jack is needed to hold the separated component.

Feed in cutting wire (3) at severance cut (2).

Place cutting wire (3) around the adhesive bead (1) (pull toward the rear).

Disconnect the adhesive bead using WIRE HANDLES .

Repeat operation on right side of vehicle and remove component.

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Preparation

Mark severance cuts (1) on new part in accordance with severance cuts on vehicle and cut.

Prepare bonding surfaces on rear axle module for BONDING LIFE MODULE WITH DRIVE MODULE .

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Remove a length of approx. 6 cm of adhesive bead (1) between the life module and drive module using a sabre saw.

Attention!

Risk of damage!

Second person needed for CHECKING AND PROTECTION of non-visible areas.

The inside reinforcement plate (2) must be easy to push in.

Repeat operation on right side of vehicle.

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Adjust rear axle module and reinforcement plates.

Position and tighten rear axle module (1) with device 2 355 218 .

Tighten rear axle module (1) on life module.

Attention!

Series screws are too long.

In areas (2), place 4 washers of 7 mm thickness.

Secure inner reinforcement plate (1) and outer reinforcement plate (2) with clamping pliers.

Drill out existing holes with 06.8-mm drill.

Repeat operation on right side of vehicle.

Remove rear axle module and reinforcement plates.

Deburr all holes.

PREPARE all bonding surfaces.

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Installation

Apply adhesive K1 onto inner reinforcement plate (1).

Slide in inner reinforcement plate (1).

Pull reinforcement plate (1) slightly inward to prevent shearing of the adhesive on the side member (2).

Repeat operation on right side of vehicle.

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Apply adhesive K2 to rear axle module.

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Position rear axle module and reinforcement plates.

Tighten rear axle module (1) with device 2 355 218 .

Tighten rear axle module (1) on life module.

Attention!

Series screws are too long since no spring struts are installed.

In areas (2), place 4 washers of 7 mm thickness.

Remove washers before installation of spring struts!

Position inner reinforcement plate (1) and outer reinforcement plate (2).

In areas (1) and (2), set 35 blind rivets N1 using blind rivet pliers 2 355 732 .

Repeat operation on right side of vehicle.

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After the adhesive hardens at the lugs, screw in 4 EMC SCREWS each.

Sand repair area with NON-WOVEN ABRASIVE S1 .

Seal blind rivet heads and EMC screws with sealant D1.

After the sealant has hardened, spray paint it in the repair area in a black matte color.