308-07A Four-Wheel Drive Systems - Vehicles With: 6-Speed Automatic Transmission - 6F35	2013 - 2014 MKZ
Diagnosis and Testing	Procedure revision date: 07/18/2013

Four-Wheel Drive Systems

Principles of Operation

The AWD system may be referred to as a 4WD system in other service information and owner literature or messages located on the message center.

The AWD system continuously monitors vehicle conditions and automatically adjusts the torque distribution between the front and rear wheels. During normal operation, most of the torque is delivered to the front wheels. If wheel slip between the front and rear wheels is detected, if the vehicle is under acceleration or if the vehicle is in an handling event, the AWD system increases and distributes torque to the rear wheels as needed. When the AWD system is functioning properly, there should be no perceived speed difference between the front and rear axles when launching or driving the vehicle on any non-uniform surface. Traction should be similar to a part time 4WD system in 4H (4X4 HIGH), but have no binding in turns.

If the spare tire is installed, the AWD system may disable automatically and enter FWD to protect driveline components. This condition may be indicated by AWD OFF message in the message center.

If there is a Check AWD message in the message center from using the spare tire, this indicator should turn off after reinstalling the repaired or replaced normal road tire and cycling the ignition OFF and ON. It is recommended to reinstall the repaired or replaced road tire as soon as possible. Major dissimilar tire sizes between the front and rear axles could cause the AWD system to stop functioning and default to FWD or damage the AWD system. If this condition occurs, a DTC will set and a Check AWD message is displayed on the message center.

AWD faults will be indicated by a driveline icon indicator in the IPC as well as the Check AWD message in the message center.

The AWD system consists of a power transfer unit, driveshaft, front and rear halfshafts, AWD relay module, PCM which includes the AWD control logic and an active torque coupling solenoid located in the Rear Drive Unit (RDU). Based on inputs to the PCM , the PCM sends a command to the AWD relay module. The amount of torque sent to the rear wheels is controlled by the AWD relay module sending a PWM duty cycle to the active torque coupling solenoid.

NOTE: The active torque coupling solenoid is not repairable. If a new component is required, the the active torque coupling solenoid and rear axle are installed as an assembly.

PCM inputs are:

Various engine and transmission signals received internally
Various signals received internally via HS CAN from the ABS module
Diagnostic information from the AWD relay module

PCM outputs are:

Solid-state clutch PWM signal to the active torque coupling solenoid

Heat Protection Rear Drive Unit (RDU)

During aggressive on road driving, the AWD system may implement a heat protection mode to protect the AWD clutch from damage. If the AWD system detects an overheat condition, it enters a locked mode. If the heat in the Rear Drive Unit (RDU) continues to rise once in the locked mode, the PCM disables the active torque coupling solenoid. This condition may be indicated by an AWD Temporarily Disabled message in the message center. To resume normal operation, stop the vehicle in a safe location and turn the engine for at least 10 minutes. After the engine is restarted and the AWD system has adequately cooled down, the AWD Temporarily Disabled message will turn off and normal AWD operation will return. In the event the engine is not stopped, the AWD Temporarily Disabled message will turn off when the system cools. Normal AWD operation returns once the message center displays AWD Restored.

Heat Protection Power Transfer Unit

During excessive use or trailer towing the AWD system may implement a heat protection mode to protect the power transfer unit from damage. The AWD system will reduce commanded torque only to situation deemed critical for minimal function. Once the maximum temperature limit is reached, then FWD only is commanded.

AWD Bar Code Identification

The AWD system on this vehicle is equipped with a bar coded active torque coupling solenoid to reduce the tolerance of electrical current to torque delivered to the active torque coupling solenoid. The active torque coupling solenoid bar code label can be found on the bottom of the Rear Drive Unit (RDU). The PCM uses this bar code information to match the clutch characteristics of the active torque coupling solenoid with the desired output torque. If the bar code information does not match the PCM information, driveline damage or driveability concerns can occur. Therefore, if the PCM needs to be replaced, the new PCM needs to be configured with the existing active torque coupling solenoid bar code information. If the rear drive axle need to be replaced, the existing PCM will need to be configured with the new active torque coupling solenoid bar code information. Carry out the AWD Drive Cycle.

Rear Drive Unit (RDU)

Item	Description
1	Active torque coupling solenoid bar code

Automatic Torque Coupling Configuration

Using the diagnostic scan tool, under the toolbox icon select Powertrain then select Automatic Traction Control Barcode Entry. Follow the instructions displayed on the scan tool.

NOTE: If the active torque coupling bar code information is not correct, Rear Drive Unit (RDU) damage or driveability concerns can occur.

Enter the 4-digit alpha numeric bar code found on the label. The scan tool verifies the digits entered are valid and displays a message if the information is not valid.

Follow the instructions displayed on the scan tool.

Road test the vehicle. Carry out the AWD drive cycle after downloading the active torque coupling solenoid bar code information to the PCM .

AWD Drive Cycle

Carry out the AWD drive cycle after downloading the active torque coupling solenoid bar code information to the PCM .

NOTE: Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

Carry out 3 accelerations from 0-30 mph (0-48 km/h) in a straight line.
- Perform this procedure at low, medium and full accelerator pedal position.
- Verify there is no perceived front wheel slip.

On dry pavement, drive the vehicle at 5 mph (8 km/h) in a fully locked turn.
- Verify there is no driveline binding.

Inspection and Verification

Verify the customer concern.

Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical	Electrical
Active Torque Coupling Solenoid (part of rear axle) Power Transfer Unit Rear Drive Unit (RDU) Halfshafts and CV joints Driveshaft and U-joints Fluid leaks Wheel/tire size and brand Matching tire size and brand Tire pressure	BJB fuse 37 (15A) Wiring harness Connector(s) Circuitry AWD relay module PCM

Clear the Diagnostic Trouble Codes (DTCs) and carry out the self-test.

If the Diagnostic Trouble Codes (DTCs) retrieved are related to the concern, GO to the DTC Chart.

If no Diagnostic Trouble Codes (DTCs) related to the concern are retrieved, GO to the Symptom Chart.

DTC Chart

DTC	Description	Action
P164D	AWD ID Block Corrupted, Not Programmed	Enter the ID located on the Rear Drive Unit (RDU) and program into the PCM .
P181F	Clutch Control System Performance	This is an internal AWD relay module fault. INSTALL a new AWD relay module. REFER to: All-Wheel Drive (AWD) Module (308-07A Four-Wheel Drive Systems - Vehicles With: 6-Speed Automatic Transmission - 6F35, Removal and Installation).
P187B	Tire Size Out of Acceptable Range - AWD Disabled / Limited Function	GO to Pinpoint Test B B
P188B	AWD Clutch Control Circuit	GO to Pinpoint Test C C
P188C	AWD Relay Module Communication Circuit	CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test. If DTC returns, GO to Pinpoint Test D D
P188D	AWD Relay Module Feedback Circuit	CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test. If DTC returns, GO to Pinpoint Test D D

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

In most circumstances, the PCM sets Diagnostic Trouble Codes (DTCs) to help guide with diagnostics. Refer to the DTC Chart before using the symptom chart. The Symptom column lists the vehicle condition. The Possible Sources column lists a detailed vehicle condition. The Action column lists the action to be performed to determine the cause of the condition. Each action lists the components that can cause the system and the individual components in that system. The components are listed in order of disassembly. Use the list of components and the required action to focus on disassembly inspections for the root cause of the concern.


Symptom	Possible Sources	Action
Unable to duplicate customer concern; no Diagnostic Trouble Codes (DTCs) present	The concern description is inaccurate	CARRY OUT the AWD System Functional Test. GO to Pinpoint Test A A
Vehicle has no or inadequate torque at rear wheels	Fuse(s) Wiring, terminals or connectors Active torque coupling solenoid AWD relay module PCM Wheels/tires Power transfer unit mechanical failure Rear axle	GO to Pinpoint Test D D REFER to: Wheels and Tires (204-04B Wheels and Tires, Diagnosis and Testing). REFER to: Transfer Case (308-07C Transfer Case - Vehicles With: 6-Speed Automatic Transmission - 6F35, Removal). REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Vehicle binds in a turn or resists turning/pulsates or shudders in a straight line	Wheels/tires Power transfer unit mechanical failure Driveshaft Wiring, terminals or connectors Active torque coupling solenoid AWD relay module Brake system Wheel bearings Halfshafts ABS system	REFER to: Wheels and Tires (204-04B Wheels and Tires, Diagnosis and Testing). REFER to: Transfer Case (308-07C Transfer Case - Vehicles With: 6-Speed Automatic Transmission - 6F35, Removal). REFER to: Driveshaft (205-01 Driveshaft, Diagnosis and Testing). GO to Pinpoint Test D D REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing). REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing). REFER to: Front Drive Halfshafts (205-04 Front Drive Halfshafts, Diagnosis and Testing). REFER to: Anti-Lock Brake System (ABS) and Stability Control - Vehicles Built Up To: 03-June-2013 (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing). REFER to: Anti-Lock Brake System (ABS) and Stability Control - Vehicles Built From: 20-May-2013 (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).
Tire/axle out of acceptable range	Wheels/tires ABS system	GO to Pinpoint Test B B
Loss of AWD function or partial AWD function	Power transfer unit overheating	INSPECT the duct that cools the power transfer unit sump is free and clear of debris.

Pinpoint Tests

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
This pinpoint test is intended to diagnose the AWD system concern without on-demand or continuous Diagnostic Trouble Codes (DTCs).

Refer to Wiring Diagrams Cell 34 for schematic and connector information.

AWD System Functional Test

Normal Operation and Fault Conditions

The AWD system is an active system, which means it not only responds to wheel slip between the front and rear axles but also has the ability to anticipate wheel slip and transfer torque to the rear wheels before the slip occurs. The AWD system is active all the time and requires no input from the operator. The AWD system continuously monitors vehicle conditions and automatically adjusts the torque distribution between the front and rear wheels. During normal operation, most of the torque is delivered to the front wheels. If wheel slip between the front and rear wheels is detected, if the vehicle is under acceleration or if the vehicle is in a handling event, the AWD system increases and distributes torque to the rear wheels as needed. When the AWD system is functioning properly, there should be no perceived speed difference between the front and rear axles when launching or driving the vehicle on any uniform surface. Traction should be similar to a part time 4WD system in 4H (4X4 HIGH), but have no binding in turns.

WARNING: When directed to drive the vehicle as part of this test, drive the vehicle on a hard surface in an area without traffic to prevent a crash. Failure to follow these instructions may result in personal injury.

NOTE: Check related modules for Diagnostic Trouble Codes (DTCs). If Diagnostic Trouble Codes (DTCs) are set in other modules, diagnose those Diagnostic Trouble Codes (DTCs) first before continuing.

PINPOINT TEST A A : AWD (ALL-WHEEL DRIVE) SYSTEM FUNCTIONAL TEST

A1 A1 CHECK FOR ACTIVE TORQUE COUPLING SOLENOID LOCK

Drive the vehicle on a dry, hard surface in turns while applying the accelerator pedal.

Is driveline wind-up present in turns?

Yes

GO to Pinpoint Test E E

No	GO to A2 A2

A2 A2 CHECK PCM (POWERTRAIN CONTROL MODULE) WHEEL SPEEDS

Ignition ON.

Drive the vehicle at 30 mph ( 48 km/h), monitor the following wheel speed sensor PIDs:
- Left Front Wheel Speed Sensor (LF_WSPD)
- Left Rear Wheel Speed Sensor (LR_WSPD)
- Right Front Wheel Speed Sensor (RF_WSPD)
- Right Rear Wheel Speed Sensor (RR_WSPD)

Are all 4 wheel speeds within 1.2 mph ( 2 km/h) of each other?

Yes

GO to A3 A3

No	REFER to: Anti-Lock Brake System (ABS) and Stability Control - Vehicles Built Up To: 03-June-2013 (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).

A3 A3 CHECK VEHICLE ACCELERATION IN A STRAIGHT LINE

Perform 3 accelerations from mph ( km/h) to 30 mph ( 48 km/h) in a straight line (1 each with low, medium and full accelerator pedal application).

Does the vehicle pulsate or shudder while accelerating?

Yes

GO to Pinpoint Test E E

No	GO to A4 A4

A4 A4 CHECK VEHICLE TURNING ABILITY

Drive the vehicle in a fully locked turn, on dry pavement, at 5 mph ( 8 km/h).

Does the vehicle bind in the turn or resist turning?

Yes

GO to Pinpoint Test E E

No	GO to A5 A5

A5 A5 CHECK TORQUE AT THE REAR WHEELS

Using the diagnostic scan tool, energize the active torque coupling solenoid to a constant 90% applied.

On dry pavement, drive the vehicle in a fully locked turn at 5 mph ( 8 km/h).

Does the vehicle bind in the turn or resist turning?

Yes

END the active command. CLEAR all Diagnostic Trouble Codes (DTCs) if set. End of System Functional Test.

No	CHECK the power transfer unit, REFER to: Transfer Case (308-07C Transfer Case - Vehicles With: 6-Speed Automatic Transmission - 6F35, Diagnosis and Testing).

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
This pinpoint test is intended to diagnose the wheels and tires, wheel speed sensors ABS module and PCM .

Refer to Wiring Diagrams Cell 34 for schematic and connector information.

Tire/Axle Out Of Acceptable Range

Normal Operation and Fault Conditions

The AWD system uses input data from the ABS module wheel speed sensor inputs to the PCM . A dissimilar spare tire size (other than the spare tire provided) or major dissimilar tire sizes or improperly inflated tires between the front and rear axles could cause the AWD system to stop functioning correctly.

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P187B	Tire Size Out of Acceptable Range - AWD Disabled / Limited Function	When the PCM detects an inappropriate size wheels/tires (greater than 5% difference in size across the front and rear axle or greater than 14% difference in size at one wheel on either the front or rear axle) installed.

Possible Sources

Wheels/tires
ABS system

PINPOINT TEST B B : TIRE/AXLE OUT OF ACCEPTABLE RANGE

B1 B1 CHECK FOR RECENT TIRE USAGE

Check with customer about recent tire usage or installation.

Was a tire recently installed on the vehicle that was not originally supplied with the vehicle or has the mini spare been used?

Yes

Tire size should not exceed Original Equipment Manufacturer (OEM) recommendations and all 4 tires should be the same size and brand. ROAD TEST the vehicle.

No	GO to B2 B2

B2 B2 CHECK TIRE SIZE AND BRAND

Check the tire size and brand.

Are all 4 tires the same size and brand?

Yes

GO to B3 B3

No	Tire size should not exceed Original Equipment Manufacturer (OEM) recommendations and all 4 tires should be the same size and brand. INSTALL new tire(s) as necessary. ROAD TEST the vehicle.

B3 B3 CHECK TIRE AIR PRESSURES

Check the air pressure in all 4 tires.

Are all 4 tires at the recommended air pressure?

Yes

GO to B4 B4

No	ADJUST tire air pressures. ROAD TEST the vehicle.

B4 B4 CHECK PCM (POWERTRAIN CONTROL MODULE) WHEEL SPEEDS

Drive the vehicle at 30 mph ( 48 km/h), monitor the following wheel speed sensor PIDs:
- Left Front Wheel Speed Sensor (LF_WSPD)
- Left Rear Wheel Speed Sensor (LR_WSPD)
- Right Front Wheel Speed Sensor (RF_WSPD)
- Right Rear Wheel Speed Sensor (RR_WSPD)

Are all 4 wheel speeds within 1.2 mph ( 2 km/h) of each other?

Yes

GO to B5 B5

The module is sending invalid wheel speed data to the ,
REFER to: Anti-Lock Brake System (ABS) and Stability Control - Vehicles Built Up To: 03-June-2013 (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).
REFER to: Anti-Lock Brake System (ABS) and Stability Control - Vehicles Built From: 20-May-2013 (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).

B5 B5 CHECK FOR CORRECT PCM OPERATION

Disconnect PCM C1381E .

Inspect the connector for damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals.

Connect PCM C1381E .

ROAD TEST the vehicle.

Operate the system and determine if the concern is still present.

Is the concern still present?

Yes

INSTALL a new ,
REFER to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 2.0L EcoBoost (184kW/250PS) - MI4, Removal and Installation).
PROGRAM the with the latest calibration. PERFORM the Transmission Strategy Download procedure,
REFER to: Transmission Strategy Download (307-01B Automatic Transmission - Vehicles With: 6-Speed Automatic Transmission - 6F35, General Procedures).
PROGRAM the with the active torque coupling solenoid bar code information, REFER to Automatic Torque Coupling (ATC) Configuration. PERFORM the Drive Cycle.

No	The system is operating correctly at this time. ROAD TEST the vehicle and PERFORM the AWD Drive Cycle.

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
This pinpoint test is intended to diagnosis the wiring, terminals, connectors, AWD relay module and PCM .

Refer to Wiring Diagrams Cell 34 for schematic and connector information.

AWD Clutch Control

Normal Operation and Fault Conditions

The AWD system uses data from other systems as inputs to the PCM . The PCM uses the inputs to determine the appropriate time to send a signal and have the AWD relay module energize the active torque coupling solenoid.

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P188B	AWD Clutch Control Circuit	When the PCM detects an open, a short to ground or voltage on the active torque coupling solenoid voltage supply and/or return circuit.

Possible Sources

Connectors damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals
Active torque coupling solenoid
PCM

PINPOINT TEST C C : AWD (ALL-WHEEL DRIVE) CLUTCH CONTROL

C1 C1 CHECK THE ACTIVE TORQUE COUPLING SOLENOID CIRCUITS

Disconnect AWD Relay Module C4379 .

Inspect the connector for damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals.

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-5		C4379-8

Is the resistance between 1 to 3 ohms?

Yes

INSTALL a new relay module.
REFER to: All-Wheel Drive (AWD) Module (308-07A Four-Wheel Drive Systems - Vehicles With: 6-Speed Automatic Transmission - 6F35, Removal and Installation).

No	GO to C2 C2

C2 C2 CHECK THE ACTIVE TORQUE COUPLING SOLENOID CIRCUITS FOR AN OPEN

Disconnect active torque coupling solenoid C4347 .

Inspect the connector for damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals.

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-5		C4347-1
C4379-8		C4347-2

Is the resistance less than 3 ohms?

Yes

GO to C3 C3

No	REPAIR the circuit.

C3 C3 CHECK THE ACTIVE TORQUE COUPLING SOLENOID CIRCUITS FOR A SHORT TO GROUND

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-5		Ground
C4379-8		Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to C4 C4

No	REPAIR the circuit.

C4 C4 CHECK THE ACTIVE TORQUE COUPLING SOLENOID CIRCUITS FOR A SHORT TOGETHER

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-5		C4347-2

Is the resistance greater than 10,000 ohms?

Yes

GO to C5 C5

No	REPAIR the circuit.

C5 C5 CHECK THE ACTIVE TORQUE COUPLING SOLENOID CIRCUITS FOR A SHORT TO POWER

Ignition ON.

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-5		Ground
C4379-8		Ground

Is any voltage present?

Yes

REPAIR the circuit.

No	GO to C6 C6

C6 C6 CHECK THE ACTIVE TORQUE COUPLING SOLENOID

Measure.

Positive Lead	Measurement / Action	Negative Lead
Component side pin 1.		Component side pin 2.

Is the resistance between 1 and 3 ohms?

Yes

INSTALL a new ,
REFER to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 2.0L EcoBoost (184kW/250PS) - MI4, Removal and Installation).
PERFORM the Transmission Strategy Download procedure, REFER to: Transmission Strategy Download (307-01B Automatic Transmission - Vehicles With: 6-Speed Automatic Transmission - 6F35, General Procedures).
PROGRAM the with the active torque coupling solenoid bar code information, REFER to Automatic Torque Coupling (ATC) Configuration. PERFORM the Drive Cycle.

No	INSTALL a new rear axle. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation). PROGRAM the PCM with the active torque coupling solenoid bar code information. REFER to Automatic Torque Coupling (ATC) Configuration. PERFORM the AWD Drive Cycle.

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
This pinpoint test is intended to diagnosis the wiring, terminals, connectors, AWD relay module and PCM .

Refer to Wiring Diagrams Cell 34 for schematic and connector information.

AWD Information Circuits

Normal Operation and Fault Conditions

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P188C	AWD Relay Module Communication Circuit	When the PCM detects an open, a short to ground or voltage on the command circuit.
P188D	AWD Relay Module Feedback Circuit	When the PCM detects an open, a short to ground or voltage on the feedback circuit.

Possible Sources

Connectors damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals
AWD relay module
PCM

PINPOINT TEST D D : AWD (ALL-WHEEL DRIVE) INFORMATION CIRCUITS

D1 D1 CHECK FOR AWD (ALL-WHEEL DRIVE) RELAY VOLTAGE

Disconnect AWD Relay Module C4379 .

Inspect the connector for damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals.

Ignition ON.

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-1		Ground

Is the voltage greater than 10 volts?

Yes

GO to D4 D4

No	GO to D2 D2

D2 D2 CHECK FUSE 37 (15A)

Ignition OFF.

Remove and check fuse 37 (15A).

Is the resistance less than 3 ohms?

Yes

GO to D3 D3

No	REPAIR the circuit.

D3 D3 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE POWER CIRCUIT FOR AN OPEN

Disconnect BCM C2280H .

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-1		C2280H-16

Is the resistance less than 3 ohms?

Yes

GO to D4 D4

No	REPAIR the circuit.

D4 D4 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE GROUND CIRCUIT FOR AN OPEN

Install fuse 37 (15A).

Ignition ON.

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-1		C4379-4

Is the voltage greater than 10 volts?

Yes

GO to D5 D5

No	REPAIR the circuit.

D5 D5 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE COMMAND AND FEEDBACK CIRCUITS FOR AN OPEN

Ignition OFF.

Disconnect PCM C1381B .

Inspect the connector for damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals.

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-6		C1381B-46
C4379-3		C1381B-60

Is the resistance less than 3 ohms?

Yes

GO to D6 D6

No	REPAIR the circuit.

D6 D6 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE COMMAND AND FEEDBACK CIRCUITS FOR A SHORT TO GROUND

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-6		Ground
C4379-3		Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to D7 D7

No	REPAIR the circuit.

D7 D7 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE COMMAND AND FEEDBACK CIRCUITS FOR A SHORT TOGETHER

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-6		C4379-3

Is the resistance greater than 10,000 ohms?

Yes

GO to D8 D8

No	REPAIR the circuit.

D8 D8 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE COMMAND AND FEEDBACK CIRCUITS FOR A SHORT TO POWER

Ignition ON.

Measure.

Positive Lead	Measurement / Action	Negative Lead
C4379-6		Ground
C4379-3		Ground

Is any voltage present?

Yes

REPAIR the circuit.

INSTALL a new relay module.
REFER to: All-Wheel Drive (AWD) Module (308-07A Four-Wheel Drive Systems - Vehicles With: 6-Speed Automatic Transmission - 6F35, Removal and Installation).
PERFORM the self-test. If P188C and/or P188D return, INSTALL a new .
REFER to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 2.0L EcoBoost (184kW/250PS) - MI4, Removal and Installation).
PERFORM the Transmission Strategy Download procedure, REFER to: Transmission Strategy Download (307-01B Automatic Transmission - Vehicles With: 6-Speed Automatic Transmission - 6F35, General Procedures).
PROGRAM the with the active torque coupling solenoid bar code information, REFER to Automatic Torque Coupling (ATC) Configuration. PERFORM the Drive Cycle.

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
This pinpoint test is intended to diagnose the wiring, terminals, connectors, wheels and tires, rear axle, ABS module, PCM and AWD relay module.

Refer to Wiring Diagrams Cell 34 for schematic and connector information.

Vehicle Binds in a Turn or Resists Turning/Pulsates or Shudders in a Straight Line

Normal Operation and Fault Conditions

Possible Sources

Wheels/tires
ABS system

PINPOINT TEST E E : VEHICLE BINDS IN A TURN OR RESISTS TURNING/PULSATES OR SHUDDERS IN A STRAIGHT LINE

E1 E1

Disconnect active torque coupling solenoid C4347 .

Inspect the connector for damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals.

Drive the vehicle in a straight line on dry pavement.

Is a pulsation or shudder still present?

Yes

REFER to: Rear Drive Axle and Differential (205-02 Rear Drive Axle/Differential, Diagnosis and Testing).

No	GO to E2 E2

E2 E2 MONITOR THE CLUTCH STATUS PID

Ignition OFF.

Connect active torque coupling solenoid C4347 .

Ignition ON.

Using the diagnostic scan tool, monitor the AWD_CLTCH_CMD# PID.

Drive the vehicle at a constant 5 mph ( 8 km/h) in tight turns on dry pavement while monitoring the active torque coupling solenoid duty cycle.

Is the duty cycle greater than 20%?

Yes

GO to E3 E3

No	GO to Pinpoint Test B B

E3 E3 CHECK FOR THE CORRECT WHEEL SPEEDS

Drive the vehicle at 30 mph ( 48 km/h), monitor the following wheel speed sensor PIDs:
- Left Front Wheel Speed Sensor (LF_WSPD)
- Left Rear Wheel Speed Sensor (LR_WSPD)
- Right Front Wheel Speed Sensor (RF_WSPD)
- Right Rear Wheel Speed Sensor (RR_WSPD)

Are all 4 wheel speeds within 1.2 mph ( 2 km/h) of each other?

Yes

GO to E4 E4

No	GO to Pinpoint Test B B

E4 E4 CHECK FOR CORRECT AWD RELAY MODULE OPERATION

Disconnect AWD Relay Module C4379 .

Disconnect active torque coupling solenoid C4347 .

Inspect the connectors for damaged or pushed-out terminals, corrosion, loose wires and missing or damaged seals.

Check the harness between the AWD relay module and the active torque coupling solenoid for damage.

Connect AWD Relay Module C4379 .

Connect active torque coupling solenoid C4347 and make sure it seats correctly.

Operate the system and determine if the concern is still present.

Is the concern still present?

Yes

INSTALL a new relay module.
REFER to: All-Wheel Drive (AWD) Module (308-07A Four-Wheel Drive Systems - Vehicles With: 6-Speed Automatic Transmission - 6F35, Removal and Installation).

No	The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ROAD TEST the vehicle.