Installing Rear Axle

WARNING: Incorrect handling of high-voltage components

Electric shock
Short circuit
Fire
Explosion
→ Only appropriately trained and authorised persons are permitted to work on high-voltage vehicles and components.

→ Required qualification: High voltage technician or high voltage expert.

→ Observe national requirements and legislation for this work.

→ Always use insulated tools, e.g. > VAS 6883 - Insulated Tool Set when working on these components. Observe general warning notes for working on the high-voltage system.

> 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE SYSTEM

Information

You will need a second mechanic to help you with this step.

install rear axle -1- .

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Rear axle
1. 1.1 Tilt and lift the rear axle -1- together with the electric motor as required and guide it into installation position from below.
  Get another person to help by checking that all components have sufficient clearance.
2. 1.2 Screw in new screws on rear axle bearing -2- as far as they will go by hand.
3. 1.3 Tighten screws on rear axle bearing -2- .
  > Tightening torque 130 Nm (96 ftlb.)
  
  > Torque angle + 180 °
Screw in and tighten new screws -2- on the rear electric motor mountings -1- .
> Initial tightening 50 Nm (37 ftlb.)

> Final tightening torque angle 60 °

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Rear electric motor mountings
Screw in and tighten new screws -2- on the front electric motor mountings -1- .
> Initial tightening 50 Nm (37 ftlb.)

> Final tightening torque angle 60 °

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Front electric motor mountings
Remove > VAS 6832/11 - assembly device for rear axle from > VAS 6832 - Master Gear unit elevating platform .
Secure coolant hoses -1 and 2- .

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Coolant hoses
1. 5.1 Push on and lock quick connectors -4- .
2. 5.2 Clip coolant hoses -1 and 2- into holder -3- .
Position electric line -2- and clip in clip -1- .

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Electric line for tyre pressure monitoring
Secure air line -1- to the rear axle housing.

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Air line on rear axle housing
1. 7.1 Clip air line -1- into clip -3- .
2. 7.2 Secure air line -1- with a new tie-wrap -2- .
Secure electric wire harness -1- on both sides of the vehicle.

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Electric wire harness
1. 8.1 Position electric wire harness -1- .
2. 8.2 Connect and lock electric plug connections -2 and 3- and clip them into holder -4- .
Install brackets -1- .

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Brackets
1. 9.1 Position brackets -1- .
2. 9.2 Screw in screws -3 and 4- as far as they will go.
3. 9.3 Tighten screws -3- .
  > Tightening torque 20 Nm (15 ftlb.)
4. 9.4 Tighten screws -4- .
  > Tightening torque 20 Nm (15 ftlb.)
5. 9.5 Only on right side:
  Clip in clip -2- .