Lincoln Corsair: Rear Electric Drive Assembly / Removal and Installation - Rear Electric Drive Assembly

Special Tool(s) / General Equipment

Removal

1.   WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

   De-energize the high-voltage system.
   Refer to: High Voltage System De-energizing (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. If necessary, drain the rear electric drive assembly oil.
   Use the General Equipment: Fluid Container

1. Remove the following items:
   1. Remove the muffler and tailpipe.
      Refer to: Muffler and Tailpipe (309-00C Exhaust System - 2.5L Duratec – Hybrid (121kW/164PS) (BG), Removal and Installation).
      
   2. Remove the rear halfshafts.
      Refer to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation).
      

1. Remove the bolt for the high-voltage battery wire harness.
   

1. Remove the bolts and position aside the high-voltage battery wire harness.
   

1. • Clamp the cooling hoses to the rear electric drive assembly.
     Use the General Equipment: Locking Pliers

   • NOTE: Be prepared to collect escaping fluid.

     Disconnect the rear electric drive assembly cooling hoses.
     Use the General Equipment: Fluid Container

1. Remove the bolt and position aside the ground wire.
   

1. Disconnect the motor vent hose and position aside.
   

1. Disconnect the axle vent hose and position aside.
   

1. Disconnect the electrical connector and the wire retainer.
   

1.   WARNING: Always secure engines, transmissions, or other heavy components to the support fixture with straps and wooden support blocks. Improperly secured assemblies could fall off the fixture, resulting in serious personal injury.

   Using a transmission jack, support the rear electric drive assembly. Install a safety strap.
   Use the General Equipment: Transmission Jack
   Use the General Equipment: Retaining Strap

1. 1. NOTE: Loosen the bolt completely and leave in place during the removal and installation.

      Loosen the rear bolts and position them out.
      
   2. Remove the front bolts and lower the rear electric drive assembly from the vehicle.
      

1. If necessary, remove the bolts and the mounting brackets.
   

Installation

1. If necessary, install the mounting brackets and the bolts.
   Torque: 66 lb.ft (90 Nm)

1. Install the rear electric drive assembly and the bolts.
   Torque: 66 lb.ft (90 Nm)

1. Remove the safety strap and the transmission jack.
   Use the General Equipment: Transmission Jack
   Use the General Equipment: Retaining Strap

1. Connect the electrical connector and the wire retainer.
   

1. Position back and connect the axle vent hose.
   

1. Position back and connect the motor vent hose.
   

1. Position back the ground wire and install the bolt.
   Torque: 106 lb.in (12 Nm)

1. • Connect the rear electric drive assembly cooling hoses.
     Use the General Equipment: Fluid Container
   • Remove the locking pliers for the cooling hoses to the rear electric drive assembly.
     Use the General Equipment: Locking Pliers

1. Position back the high-voltage battery wire harness and install the bolts.
   Torque: 97 lb.in (11 Nm)

1. Install the bolt for the high-voltage battery wire harness.
   Torque: 97 lb.in (11 Nm)

1. Install the following items:
   1. Install the rear halfshafts.
      Refer to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation).
      
   2. Install the muffler and tailpipe.
      Refer to: Muffler and Tailpipe (309-00C Exhaust System - 2.5L Duratec – Hybrid (121kW/164PS) (BG), Removal and Installation).
      

1. Connect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Repower the high-voltage system. Refer to: High Voltage System De-energizing (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Fill and bleed the electric powertrain cooling system.
   Refer to: Cooling System Filling and Bleeding (303-03D Electric Powertrain Cooling - 2.5L Duratec – Hybrid (121kW/164PS) (BG), General Procedures).
   

1. NOTE: This step is not necessary when installing a new component.

   Remove the fill plug and fill the front electric drive assembly oil. Install the fill plug.
   Refer to: Specifications (302-02 Rear Electric Drive Assembly) .
   Torque: 177 lb.in (20 Nm)

1. Carry out a road test.
   

1. Remove the fill plug. Check and top off the front electric drive assembly oil level. Install the fill plug.
   Refer to: Specifications (302-02 Rear Electric Drive Assembly) .
   Torque: 177 lb.in (20 Nm)

1. NOTE: This step is only necessary when installing a new component.

   Using the scan tool, CARRY OUT the Electric Motor Resolver Offset Programming in the SOBDMB .
   Refer to: Electric Drive Assembly Strategy Download (302-02 Rear Electric Drive Assembly, General Procedures).
   

1. NOTE: This step is only necessary when installing a new S-ISC (secondary-inverter system controller) - SOBDMB .

   Perform the PATS initialization procedure.
   Refer to: Module Programming (418-01 Module Configuration, General Procedures).