Check Of Drive Module (Aluminum) Rep-Alg-RAI0141-4105101_STRUKTUR - V.6

The Drive module consists of extruded profiles and cast parts in aluminum.

Cast part are used as shock tower and as rear axle module. Any other components are extruded profiles.

Use a straightening system or beam compass to check for damage (deformation).

For visual inspection in case of doubt, demobilize adjacent components.

Extruded profiles and cast parts that exhibit visible or measurable deformation must be replaced.

The relative component must be replaced when showing sharp-edged damages or cracks.

Example rear axle module:

The rear axle module must be replaced if the bearing bracket of the rubber mount is broken.

There are exceptions for the following components:

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Threaded connection for the front deformation element.
When the deformation element is screwed to the side member (1), the side member is deformed.

In the case of a damage of the deformation element, the side member must be replaced only if the signaled values are exceeded.

Dimension (A) = 5 mm.

Dimension (B) = 4 mm (outer or inner).

Pressure marks with a maximum depth of 1 mm are permitted along the line (2).

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Screw connection for the rear deformation element.
Pressure marks in the areas (1) due to the deformation element's threaded connection threads are permissible.

When there is damage to the deformation element, the rear axle module must be replaced only if the specified values are exceeded.

Dimension (A) = 2 mm.

NOTE: Hole (2) Ø14 mm.
Hole (3) elongated hole 16x14 mm.

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Connection of left and right tension struts (1) to the vertical strut (2)
If there is deformation of the vertical strut in the areas (3) in the vehicle's longitudinal direction (X direction), the vertical strut must be replaced only if the indicated values are exceeded.

Dimension (A) = 2 mm.

If there are cracks, the vertical strut (2) must be replaced.

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Radiator bracket (1)
If deformed, the holder (1) can be straightened. After the weld seam (2) is straightened, check visually for cracks.

If the welded seam is cracked, the SIDE MEMBER must be replaced.

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Bridge (1) on the Drive module in the area of the high-voltage battery
The bridge (1) serves to protect the screws (2) from damage.

For damage up to 7 mm deep, deburr the damaged area and paint. The bridge can be grinded so that it is flush.

If necessary, replace the damaged screws (2) of the high-voltage battery.

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Grind bridge (1) in damaged area (marked with arrow) until a fluid transition (2) forms.

No notches may remain.

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U section (1) on the cross member
The U section (1) serves to protect the screw from damage.

For damage up to 2 mm deep, deburr the damaged area and paint.

For damage deeper than 2 mm, the cross member must be replaced.

Replace damaged screw, if necessary.

The seat cross members must not be replaced individually. If the seat cross member is damaged, the bodyshell must be replaced.

Reshaping or heating extruded profiles and cast parts is not permitted!

Failure to comply with this requirement would have the following results:
- If there is reshaping, weld seam in the area will tear.
- In the case of reshaping, the material loses up to 40 % of its original strength.
- In the case of heating, the material loses up to 40 % of its original strength.
Gap dimensions of doors, hood and trunk lid can be found in the vehicle-specific repair instructions.