2026-10-16

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

Correction code 40014802 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.

  • 2026-10-12: Released new procedure.

Torque Specifications

Table 1. Torque Specifications: Assembly - Bulkhead Resolver Connector - Rear Drive Unit (4DU) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x3) that attach the bulkhead resolver connector to the drive unit
8 Nm (5.9 lbs-ft)
  • Ratchet/torque wrench
  • Torx T25 socket
Replace 1015888-00-C
4DU oil drain plug
15 Nm (11.1 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 8 mm socket
  • Torque wrench with angle measurement
Reuse
4DU oil fill plug
15 Nm (11.1 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 8 mm socket
  • Torque wrench with angle measurement
Reuse

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Raise the vehicle fully and lower the lift onto locks.
    CAUTION
    Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.
  3. Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  4. Release the hose clip from the resolver cover, then rotate the clip 90 degrees counterclockwise to facilitate removal of the bulkhead resolver connector assembly.
  5. Disconnect the resolver connector by releasing the locking tab.
    Note
    Move aside the harness branch as needed.
  6. Remove and discard the bolts (x3) that attach the bulkhead resolver connector to the drive unit, then remove the bulkhead resolver connector assembly.
    Note
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Torx T25 socket

Install

  1. Lightly coat the O-rings with clean KAF1 oil, and then install new bolts (x3) to attach the bulkhead resolver connector to the drive unit.
    8 Nm (5.9 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Torx T25 socket
  2. Connect the resolver connector and engage the locking tab.
  3. Rotate the hose clip 90 degrees clockwise and then secure the clip to the resolver cover.
  4. Position the oil drain container underneath the rear of the vehicle.
  5. Remove the fill plug from the rear drive unit.
    Note
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
    • Torque wrench with angle measurement
  6. Remove the oil drain plug from the rear drive unit.
    Note
    Some fluid will drain out.
    Note
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  7. Pull the red tab to disengage lock and then pull it again to release the oil pump harness connector.
  8. Connect the 12V power supply to the oil pump switchbox, and then secure the oil pump switchbox to the oil pump connector.
  9. Run the oil pump power supply for 1 minute and drain the remaining oil from the 4DU 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.
  10. Release the power supply and the oil pump switchbox from the oil pump connector.
  11. Install the oil drain plug onto the 4DU drive unit.
    15 Nm (11.1 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
    • Torque wrench with angle measurement
    Note
    Verify the O-ring is not damaged and replace the plug as needed.
  12. 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.
  13. 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.
  14. Fully submerge the input hose of the fluid transfer pump into the measuring container.
  15. 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.
  16. Secure the oil fill plug onto the 4DU drive unit.
    15 Nm (11.1 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
    • Torque wrench with angle measurement
    Note
    Verify the O-ring is not damaged and replace the plug as needed.
  17. Connect the oil pump connector.
  18. Spray the working area of the rear drive unit with brake cleaner, and then wipe off residual fluid with a clean shop towel.
  19. Remove the oil drain container from underneath the rear drive unit.
  20. Install the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  21. Lower the vehicle fully.
  22. Open the LH front door and lower the LH front window.
  23. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox (Connect and Disconnect).
  24. Perform the routine: TEST-SELF_DIR_X_OIL-PUMP-PRESSUREvia Toolbox:(link)
  25. Disconnect the laptop from the vehicle. See Toolbox (Connect and Disconnect).
  26. Exit Service Mode Plus. See Service Mode Plus.
  27. Raise the LH front window and close the LH front door.
  28. Remove the lift arms from below the vehicle.