2026-10-14

Assembly - Bulkhead Resolver Connector - Rear Drive Unit (4DU) (Remove and Replace)

Correction code 4001040802 FRT 0.48 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Remove

  1. Remove the rear aero shield panel. See Aero Shield - Rear (Remove and Replace).
  2. Release the hose clip from the resolver cover, and then rotate the clip 90 degrees counterclockwise to facilitate removal of the bulkhead resolver connector assembly.
  3. Release the locking tab and disconnect the resolver connector.
    Note
    Move the harness branch aside as needed.
  4. Remove and discard the bolts (x3) that secure the bulkhead resolver connector assembly, and then remove the assembly from the vehicle.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit

Install

  1. Lightly coat the o-rings on the new connector with clean KAF1 oil.
  2. Install new bolts (x3) that secure the bulkhead resolver connector assembly.
    8 Nm (5.9 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit
  3. Connect the resolver connector and engage the locking tab.
  4. Install the hose clip to the resolver cover, and then rotate the clip 90 degrees clockwise to secure the clip.
  5. Position an oil drain container to underneath the drive unit.
  6. Remove the fill plug from the drive unit. See .Fill/Drain Plug (Remove and Replace)
  7. Release the oil drain plug from the drive unit.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm hex
  8. Disconnect the oil pump connector.
    Note
    Do not push down on the red tab. Pull the red tab to disengage the lock, then pull it again to release the connector.
  9. Connect the 12V power supply to the oil pump switchbox, and then secure the oil pump switchbox to the oil pump connector.
  10. Run the oil pump power supply for 1 minute and drain the remaining oil from the drive unit.
    Note
    Take precaution because the oil will shoot out at a wide angle. Adjust the position of the oil drain container as needed. Do not run oil pump dry for extended period of time.
  11. Release the power supply and the oil pump switchbox from the oil pump connector.
  12. Install the oil drain plug to the drive unit.
    15 Nm (11.1 lbs-ft)
    Note
    Verify the O-ring is not damaged and replace the plug as needed.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm hex
  13. Set up the fill kit with KAF1 and fill the measuring container to 2.5 L (2500 ml).
    Note
    • The 4DU drive unit takes 2.3 L of fluid. However, add extra oil to the container to prevent underfill and additional air being injected.
    • Only use KAF1 fluid for the 4DU drive unit. Do not interchange or mix oil types.
  14. Insert the output hose of the fluid transfer pump into the fill hole of the rear drive unit until fully seated, then pull back 5 mm.
  15. Fully submerge the input hose of the fluid transfer pump into the measuring container.
  16. Pump 2.3L/2300mL of KAF1 gearbox fluid into the rear drive unit.
    Note
    Make sure the input hose end remains submerged, so that air is not pumped into the gearbox.
    Note
    When properly filled, there should be 200ml or less of gearbox fluid left in the measuring container.
  17. Install the fill plug to the drive unit. See .Fill/Drain Plug (Remove and Replace)
  18. Connect the oil pump connector and engage the locking tab.
  19. Spray the working area of the rear drive unit with brake cleaner, and then wipe off residual fluid with a clean shop towel.
  20. Remove the oil drain container from underneath the rear drive unit.
  21. Install the rear aero shield panel. See Aero Shield - Rear (Remove and Replace).
  22. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox (Connect and Disconnect).
  23. On the laptop, click the Actions tab, type "Oil Pump Low pressure Test - Rear Drive Unit" into the search field, click TEST-SELF_DIR_X_OIL-PUMP-PRESSUREvia Toolbox:(link), click Run, and allow the routine to complete.
  24. Disconnect the laptop.
  25. Exit Service Mode. See Service Mode Plus.