41 11 430 Replace Front Axle Module
Special tools required:
Compliance with the following points is mandatory before beginning work:
- DISCONNECT HIGH-VOLTAGE SYSTEM FROM POWER .
- Observe SAFETY INFORMATION for handling electric vehicles.
Read contents of BODY, GENERAL .
The following body components are required:
- (1) Front axle module
- (2) Outside reinforcement plate on drive module (quantity: 2)
- (3) Inside reinforcement plate on drive module (quantity: 2)
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K1 | 1 |
| Adhesive K2 | 2 |
| Cleaning agent R1 | 1 |
| Cleaning agent R2 | 1 |
| Blind rivet N1 | 70 |
| EMC screws | 16 |
| Non-woven abrasivesS1 | |
| Sealant D1 | 1 |
| Spray can, black, matte | 1 |
Necessary preliminary tasks:
- Remove HIGH-VOLTAGE BATTERY UNIT .
Insert special tool 2 355 218 on both sides of vehicle at front on side frame and lock.
Lift motor vehicle at front using special tool 2 355 218 .
Load vehicle in footwell before stripping it down or secure it with a tensioning strap (1).
The tensioning force of the tensioning strap must be equal to or greater than 2000 Dan (2 t).
Strip down vehicle.
Removal
Release left and right screws (1).
Tightening torque 41 11 Az .
Roughly cut cross member (1).
Roughly cut side member with wheel arch (1) along line (2) with RECIPROCATING SAW .
Second person needed to hold the cut-off component.
Attention!
Risk of damage!
Free end of saw blade must not come into contact with carbon parts.
Repeat operation on right side of vehicle.
Attention!
Point flame of autogenous torch only at components made from aluminium. Flame is not to contact carbon parts under any circumstances.
Heat area (1) with autogenous torch.
Release component with pliers as far as possible starting from the top.
Roughly cut jacking point (1) along line (2) with RECIPROCATING SAW .
Attention!
Risk of damage!
Free end of saw blade must not come into contact with carbon parts.
Jacking point is bonded to Life module in areas (3).
Attention!
Point flame of autogenous torch only at components made from aluminium. Flame is not to contact carbon parts under any circumstances.
Heat areas (3) with autogenous torch.
Release cut-off jacking point (4).
Repeat operation on right side of vehicle.
Jacking point (1) is bonded to Life module in area (2).
Lay cutting wire (3) around adhesive bead (1).
Disconnect the adhesive bead using WIRE HANDLES .
Repeat operation on right side of vehicle.
Attention!
Risk of damage!
Saw blade must not touch carbon parts.
Cut adhesive bead (1) with RECIPROCATING SAW .
Protect bulkhead in area (2) with a PANEL held by a second person.
View from inside/below:
Attention!
Risk of damage!
Saw blade must not touch carbon parts.
Second person needed for CHECKING AND PROTECTION of non-visible areas.
Cut adhesive beads (1) from inside with reciprocating saw.
Cut adhesive bead (2) from outer side with reciprocating saw.
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) = 470 mm.
Repeat operation on right side of vehicle.
A suitable jack is needed to hold the separated component.
Lay cutting wire (3) around adhesive bead (1).
Feed in cutting wire at severance cut (2).
Disconnect the adhesive bead using WIRE HANDLES .
Repeat operation on right side of vehicle and remove component.
Preparation
Mark severance cuts (1) on new part in accordance with severance cuts on vehicle and cut.
Prepare bonding surfaces on front axle module for BONDING LIFE MODULE WITH DRIVE MODULE .
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.
Position front axle module with device 2 355 218 and screw on.
Screw wheel arches (1) to carrier supports.
Secure inner reinforcement plate (1) and outer reinforcement plate (2) with clamping pliers.
Drill out existing holes with Ø6.8-mm drill.
Repeat operation on right side of vehicle.
Remove front axle module and reinforcement plates.
Deburr all bore holes.
PREPARE all bonding surfaces.
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.
Apply adhesive K2 to front axle module.
Position front axle module with device 2 355 218 and screw on.
Screw wheel arches (1) to carrier supports.
Position inner reinforcement plate (1) and outer reinforcement plate (2).
In areas (1) and (2), use 35 blind rivets N1.
Repeat operation on right side of vehicle.
After hardening of adhesive at tabs screw in 4 EMC SCREWS in each case.
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.