4wd Problem

[Humper]

Started up after clocking out only to find a 4WD Fault Service Required Error, took it to the local Ford but couldn't get in for a week, they advised it wasn't a problem to keep driving.
Hooked it up to my scanner at home and got the following DTCs.
4WD/AWD Power Transfer Unit Position Sensor A.
4WD/AWD Power Transfer Unit Position Sensor B.
4WD/AWD Power Transfer Unit Position Temperature Sensor.
Anyone had any Same / Similar problems, and what the fix was, I'm still under warranty so not worried about that, more concerned about not having a vehicle to get to work for a few days if it's a big job, it does sound like these are sensors, so hopefully it's just plug in and be done real quick.

 

[Ford Motor Company]

Hi Mick, If you’d like further assistance regarding the error message, feel free to send us a private message with your VIN and local Ford dealer. Thank you!

 

[RSH]

I recently had a 4WD fault with my Badlands, it also triggered a number of other faults. The dealer replaced the 4WD module, it was not communicating with the other hardware. Unless you are still within the 3 year 36k mile bumper to bumper warranty or have an extended warranty that covers the complete vehicle you'll be paying out of your own pocket because the module is not covered by the 5 year 60k mile powertrain warranty, the module is considered an electrical part, even though it controls the powertrain.
You can keep driving, the Sport will default to front wheel drive, you'll just keep having the 4WD fault and possibly other errors pop up on the dash display.

 

[Humper]

RSH. Thanks for the reply it's a 24 with just over 2k miles, so should be still on bumper to bumper warranty.

 

[BravoAlpha]

Started up after clocking out only to find a 4WD Fault Service Required Error, took it to the local Ford but couldn't get in for a week, they advised it wasn't a problem to keep driving.
Hooked it up to my scanner at home and got the following DTCs.
4WD/AWD Power Transfer Unit Position Sensor A.
4WD/AWD Power Transfer Unit Position Sensor B.
4WD/AWD Power Transfer Unit Position Temperature Sensor.
Anyone had any Same / Similar problems, and what the fix was, I'm still under warrant so not worried about that, more concerned about not having a vehicle to get to work for a few days if it's a big job, it does sound like these are sensors, so hopefully it's just plug in and be done real quick.



if there was nothing significant, to you’re knowledge, that occured to cause this then I would disconnect the battery and let it set. Overnight even. Reconnect and I’ll bet (50/50) the fault clears.

 

[Humper]

Yeah, I got a typo. Thanks for pointing that out, appreciate the help!

 

[Dude]

Yeah, I got a typo. Thanks for pointing that out, appreciate the help!

Nah I was just adding to your funny comment, hadn’t heard it before now

 

[Chiefthepup]

Mine popped up due to a bad ground. Albeit my own doing when I installed some aux lighting but I’ve read some posts on here discussing grounds being loose from factory or not long after purchasing. Might be worth visually inspecting ? Keep us updated!

 

[Humper]

I had a bad ground a few weeks ago that caused all sorts of issues, the ground located near the drivers side fender was loose. I fixed that and it's been fine since, I did check it again and it's still tight. I tried disconnecting the battery cables for a cpl of hours, first start the 4wd issue popped right back up.

 

[RSH]

When my 4WD fault first started I searched the internet about the issue, a number of AWD Escapes, Corsair and Edges would display the same fault. On one of the forums I visited, some European guy figured out it was a grounding issue inside the AWD/4WD module itself, he came up with a fix to add another ground to the module which permanently cured the fault, others performed his fix and were also successful.

Also if you search the NTSB site the Ford AWD/4WD fault lists a lot of complaints especially because Ford doesn't cover the module with the powertrain warranty.

Your 4WD error could be caused by something else, you won't know until it's officially diagnosed.
The vehicle is under warranty, Ford will fix it and you'll be good as new.

 

[Dude]

This is from Explorer ST forum … not saying this is applicable to any Bronco Sport but gives you an idea of the trouble various Ford model owners are having with the ground

for those inclined to fix an out of warranty issue with the module would be best to obtain wiring diagrams and verify anything you attempt to do on your own

“For those of you (EXPLORER OWNERS) getting this 4wd fault and out of warranty. Easy fix. No need to change AWD module. Slide seat drivers seat forward and lift carpet to gain access from behind.

Here is a video of how to get to the AWD module. No need to remove seat. Disconnect plug and remove cover from plug to expose wires. Find pin 46 and strip the wire insulation about 1/8 inch to expose copper wire. Now cut a seperate wire about 1 to 2 feet in length and add connector to ground wire to frame. And secure to 10mm stud holding awd module. Secure other end to pin 46 wire and put everything back together. It took 10 minutes. No more faults . No more codes. $0 spent. It's not the AWD module going bad. It's the module losing ground, because it gets it from the frame with the attached bolts. I tried cleaning and making it work but no luck. So I tried doing the TSB 23-2061 that someone recommended in this group and it worked. I figured I'd post to help others because the TSB calls to remove the seat. No need to remove seat if your ok being in uncomfortable position for few minutes.”

 

[magicbus]

A couple of months ago I pulled an Explorer with this same issue out of a hole on the beach. He was one unhappy camper.

 

[RSH]

In the research I did the circuit board inside the module is grounded to the housing and the housing is grounded to the body with the attachment hardware. Apparently the circuit board can loose it's ground connection to the housing over time which causes the AWD/4WD fault as well as other errors. Fortunately the circuit board also has a ground connection to unused pin 46 of the connector which can be accessed to attach a separate ground wire that can be grounded to the body which intern completes the ground path of the circuit board. Once the circuit board is properly grounded the module functions correctly and the AWD/4WD fault is mitigated and allows the drivetrain to function normally.

The above is basically the same information as in the video that Dude posted.
The reason cleaning the module grounding points didn't work to restore the module ground is most likely because the circuit boards ground path inside the module is compromised and the only way to restore the ground is to attach an external ground to pin 46 that the circuit board is still connected to.

 

[Humper]

In the research I did the circuit board inside the module is grounded to the housing and the housing is grounded to the body with the attachment hardware. Apparently the circuit board can loose it's ground connection to the housing over time which causes the AWD/4WD fault as well as other errors. Fortunately the circuit board also has a ground connection to unused pin 46 of the connector which can be accessed to attach a separate ground wire that can be grounded to the body which intern completes the ground path of the circuit board. Once the circuit board is properly grounded the module functions correctly and the AWD/4WD fault is mitigated and allows the drivetrain to function normally.

The above is basically the same information as in the video that Dude posted.
The reason cleaning the module grounding points didn't work to restore the module ground is most likely because the circuit boards ground path inside the module is compromised and the only way to restore the ground is to attach an external ground to pin 46 that the circuit board is still connected to.

I'll give this a shot this weekend

 

[RSH]

I'll give this a shot this weekend

I wouldn't mess with it.
Your Sport is basically new and still under the bumper to bumper warranty, let Ford deal with it, that's what the warranty is for.

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