Ford Ecosport: Four-Wheel Drive Systems / Diagnosis and Testing - Four-Wheel Drive Systems

Ford Ecosport 2014-2024 Service and Repair Manual / Manual Transmission, Clutch, Transfer Case and Power Transfer Unit / Four-Wheel Drive Systems / Diagnosis and Testing - Four-Wheel Drive Systems

DTC Chart: AWD System - PCM

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).

Network DTC s (U-codes) are often a result of intermittent concerns such as damaged wiring or low battery voltage occurrences. Additionally, vehicle repair procedures, such as module reprogramming, often set network DTC s. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To prevent repeat network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle battery.
REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).

DTC Chart - PCM

DTC	Description	Action
P164D	AWD ID Block Corrupted, Not Programmed	PROGRAM the PCM with the Active Torque Coupling (ATC) solenoid bar code information using Automatic Torque Coupling Configuration. REFER to: Four-Wheel Drive Systems - System Operation and Component Description (308-07A Four-Wheel Drive Systems, Description and Operation).
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, Removal and Installation).
P187B	Tire Size Out of Acceptable Range - AWD Disabled / Limited Function	GO to Pinpoint Test B
P188B	AWD Clutch Control Circuit	GO to Pinpoint Test C
P188C	AWD Relay Module Communication Circuit	CLEAR the DTC s. REPEAT the self-test. If the DTC returns, GO to Pinpoint Test D
P188D	AWD Relay Module Feedback Circuit	CLEAR the DTC s. REPEAT the self-test. If the DTC returns, GO to Pinpoint Test 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 DTC s 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 Chart - Four-Wheel Drive Systems

Condition	Possible Sources	Actions
Unable to duplicate customer concern; no DTC present	The concern description is inaccurate	CARRY OUT the AWD System Functional Test. GO to Pinpoint Test A
Vehicle has no or inadequate torque at rear wheels	Fuse Wiring, terminals or connectors Active Torque Coupling (ATC) solenoid Active Torque Coupling (ATC) Clutch AWD Relay Module PCM	GO to Pinpoint Test C
	Wheels/tires	Check wheels and tires for damage. REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis and Testing).
	Rear axle	Check rear axle for damage. REFER to: Rear Drive Axle and Differential (205-02 Rear Drive Axle/Differential, Diagnosis and Testing).
	PTU mechanical failure	Check PTU for damage. REFER to: Transfer Case (308-07B Transfer Case - 6-Speed Automatic Transmission – 6F35, Diagnosis and Testing).
Vehicle binds in a turn or resists turning/pulsates or shudders in a straight line	Wheels/tires	Check wheels and tires for damage. REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis and Testing).
	Wiring, terminals or connectors	GO to Pinpoint Test E
	Driveshaft	Check driveshaft for damage. REFER to: Driveshaft (205-01 Driveshaft, Diagnosis and Testing).
	Wiring, terminals or connectors Active Torque Coupling (ATC) solenoid Active Torque Coupling (ATC) Clutch AWD Relay Module	GO to Pinpoint Test E
	PTU mechanical failure	Check PTU for damage. REFER to: Transfer Case (308-07B Transfer Case - 6-Speed Automatic Transmission – 6F35, Diagnosis and Testing).
	Driveshaft	Check driveshaft for damage. REFER to: Suspension System - AWD (204-00 Suspension System - General Information, Diagnosis and Testing).
	Wheel bearings	Check wheel bearings for damage. REFER to: Suspension System - AWD (204-00 Suspension System - General Information, Diagnosis and Testing).
	ABS	CHECK the ABS . REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).
	Halfshafts	Check the halfshafts for damage. REFER to: Rear Drive Halfshafts (205-05 Rear Drive Halfshafts, Diagnosis and Testing).
Tire/axle out of acceptable range	Wheels/tires ABS	GO to Pinpoint Test B

Pinpoint Tests

PINPOINT TEST A: AWD (ALL-WHEEL DRIVE) 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.

Possible Sources

Wiring, terminals or connectors
Wheels/tires

Visual Inspection and Pre-checks

ABS sensor wiring
Constant velocity joints
Driveshaft
Halfshafts
Tire size
Tire wear
U-joints

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.

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

GO to A2

A2 CHECK ABS WHEEL SPEEDS

Using a scan tool, drive the vehicle at 30 mph ( 48 km/h) and monitor the following wheel speed sensor PID s:
- 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

No	REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).

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

GO to 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

GO to A5

A5 CHECK TORQUE AT THE REAR WHEELS

Using the diagnostic scan tool, energize the Active Torque Coupling (ATC) 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 DTC s if set. End of System Functional Test. The system is operating correctly at this time.

No	CHECK the Power transfer unit (PTU). REFER to: Transfer Case (308-07B Transfer Case - 6-Speed Automatic Transmission – 6F35, Diagnosis and Testing).

PINPOINT TEST B: DTC P187B

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 Condition
PCM P187B:00	Tire Size Out of Acceptable Range - AWD Disabled / Limited Function: No Sub Type Information	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

Wiring, terminals or connectors
Wheels/tires
ABS system

Visual Inspection and Pre-checks

Inspect for correct tire size and inflation.

B1 CHECK FOR RECENT DIFFERENT SIZED TIRE USAGE

Check with customer about recent tire changes 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

The concern may have been caused by the previously mismatched tires. VERIFY the tires do not exceed Original Equipment Manufacturer (OEM) recommendations and all 4 tires are the same size.

GO to 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

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.

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

No	ADJUST tire air pressures to specifications.

B4 CHECK ABS 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

No	The ABS module is sending invalid wheel speed data to the PCM , REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).

B5 CHECK FOR CORRECT ABS AND AWD (ALL-WHEEL DRIVE) SYSTEM OPERATION

Ignition OFF.

Disconnect all ABS , AWD relay module, and Active Torque Coupling (ATC) solenoid connectors.

Check for the following:
- corrosion (install new connector or terminals – clean module pins)
- damaged or bent pins – install new terminals/pins
- pushed-out pins – install new pins as necessary

Reconnect all ABS , AWD relay module, and Active Torque Coupling (ATC) solenoid connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

CHECK OASIS for any applicable TSB s. If a TSB exists for this concern, DISCONTINUE this test and FOLLOW TSB instructions. If no TSB s address this concern, INSTALL a new ABS .
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).

No	The system is operating correctly at this time. The concern may have been caused by module connections. Address the root cause of any connector or pin issues.

PINPOINT TEST C: DTC P188B

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

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 (ATC) solenoid.

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Condition
PCM P188B:00	All Wheel Drive Clutch Control Circuit: No Sub Type Information	When the PCM detects an open, a short to ground or voltage on the Active Torque Coupling (ATC) solenoid voltage supply and/or return circuit.

Possible Sources

Wiring, terminals or connectors
Active Torque Coupling (ATC) solenoid (part of the Rear Drive Unit (RDU))
Active Torque Coupling (ATC) Clutch
AWD relay module
PCM

Visual Inspection and Pre-checks

Active torque coupling (ATC) solenoid harness

C1 CHECK THE ACTIVE TORQUE COUPLING SOLENOID

Ignition OFF.

Disconnect Active Torque Coupling (ATC) Solenoid C4347 .

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C4379-5 C4379-8

Is the resistance between 1 and 5 ohms?

Yes

INSTALL a new AWD relay module.
REFER to: All-Wheel Drive (AWD) Module (308-07A Four-Wheel Drive Systems, Removal and Installation).

No	If the resistance is less than 1 ohm, repair the circuit for a short to ground. If the resistance is greater than 5 ohms, GO to C2

C2 CHECK THE ATC SOLENOID CIRCUITS FOR AN OPEN

Disconnect ATC Solenoid C4347 .

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

Measure:
Click to display connectors

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

No	REPAIR the circuit.

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

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C4379-5 Ground

C4379-8 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to C4

No	REPAIR the circuit.

C4 CHECK THE ATC SOLENOID CIRCUITS FOR A SHORT TOGETHER

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C4379-5 C4379-8

Is the resistance greater than 10,000 ohms?

Yes

GO to C5

No	REPAIR the circuit.

C5 CHECK THE ATC SOLENOID CIRCUITS FOR A SHORT TO POWER

Ignition ON.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C4379-5 Ground

C4379-8 Ground

Is any voltage detected?

Yes

REPAIR the circuits.

GO to C6

C6 CHECK THE ATC SOLENOID

Ignition OFF.

Measure the component side resistance between.

Positive Lead Measurement / Action Negative Lead

C4347-1 C4347-2

Is the resistance between 1 to 5 ohms?

Yes

GO to C7

INSTALL a new active torque coupling clutch.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
PROGRAM the PCM with the ATC solenoid bar code information. REFER to: Active On-Demand Coupling Configuration (205-02 Rear Drive Axle/Differential, General Procedures).
PERFORM the AWD Drive Cycle.

C7 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.

Check for the following:
- corrosion (install new connector or terminals - clean module pins)
- damaged or bent pins - install new terminals/pins
- pushed-out pins - install new pins as necessary

Reconnect the PCM connectors. Make sure they seat and latch correctly.

Operate the system and verify the concern is still present

Is the concern still present?

Yes

CHECK OASIS for any applicable TSB s. If a TSB exists for this concern, DISCONTINUE this test and FOLLOW TSB instructions. If no TSB s address this concern,

Click here to access Guided Routine (PCM).

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

PINPOINT TEST D: DTCS P188C, P188D

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

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 to the AWD relay module to energize the Active Torque Coupling (ATC) solenoid. The PCM communicates this signal on the AWDC or AWD Command circuit. The AWD relay module provides feedback on the AWDM or All wheel drive monitor circuit.

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Condition
PCM P188C:00	All Wheel Drive Relay Module Communication Circuit: No Sub Type Information	The AWD relay module did not receive a valid command from the PCM on the AWDC circuit.
PCM P188D:00	All Wheel Drive Relay Module Feedback Circuit: No Sub Type Information	The PCM did not receive a valid signal from the AWD Relay Module on the AWDM circuit.

Possible Sources

Wiring, terminals or connectors
AWD relay module
PCM

Visual Inspection and Pre-checks

BJB fuse 9 (5A)

D1 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY VOLTAGE CIRCUIT

NOTE: Fuse 9 (5A) protects multiple components. Check related systems that may be inoperative.

Ignition OFF.

Disconnect AWD Relay Module C3841 .

Inspect the connectors 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 11 volts?

Yes

GO to D2

No	VERIFY BJB fuse 9 (5A) is OK. If OK, REPAIR the open circuit. If not OK, REFER to the Wiring Diagrams manual to identify possible causes of the circuit short. CLEAR the DTC s.

D2 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE GROUND CIRCUIT FOR AN OPEN

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C3841-1 C3841-4

Is the voltage greater than 11 volts?

Yes

GO to D3

No	REPAIR the circuit.

D3 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE COMMAND AND FEEDBACK CIRCUITS FOR A SHORT TO VOLTAGE

Ignition OFF.

Disconnect the PCM C1915B .

Ignition ON.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C4379-6 Ground

C4379-3 Ground

Is any voltage present?

Yes

REPAIR the circuit.

GO to D4

D4 CHECK THE AWD (ALL-WHEEL DRIVE) RELAY MODULE COMMAND AND FEEDBACK CIRCUITS FOR A SHORT TO GROUND

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C4379-6 Ground

C3841-3 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to D5

No	REPAIR the circuit.

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

Measure:
Click to display connectors
For 2.0L

Positive Lead Measurement / Action Negative Lead

C3841-6 C1915B-46

C3841-3 C1915B-60

Is the resistance less than 3 ohms?

Yes

GO to D6

No	REPAIR the circuit.

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

Measure.
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C3841-6 C3841-3

Is the resistance greater than 10,000 ohms?

Yes

GO to D7

No	REPAIR the Circuit.

D7 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect all PCM and AWD Relay Module connectors.

Clear all DTCs

Perform PCM KOER Self Test.

Did DTC P188C or P188D reset?

Yes

For P188C,

Click here to access Guided Routine (PCM).
For P188D, INSTALL a new AWD Relay Module.
REFER to: All-Wheel Drive (AWD) Module (308-07A Four-Wheel Drive Systems, Removal and Installation).

No	The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

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

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

Normal Operation and Fault Conditions

Possible Sources

Wiring, terminals and connectors
Wheels/tires
ABS system
AWD relay module
Active Torque Coupling (ATC) Clutch

Visual Inspection and Pre-checks

Wheel speed sensor wiring harness

E1 CHECK FOR TORQUE AT THE REAR WHEELS

Ignition OFF.

Disconnect active torque coupling (ATC) 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).

GO to E2

E2 MONITOR THE CLUTCH STATUS PID

Ignition OFF.

Connect active torque coupling (ATC) 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 (ATC) solenoid duty cycle.

Is the duty cycle greater than 20%?

Yes

GO to E3

No	GO to Pinpoint Test A

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

No	GO to Pinpoint Test B

E4 CHECK FOR CORRECT AWD (ALL-WHEEL DRIVE) RELAY MODULE OPERATION

Disconnect the AWD relay module C3841 .

Disconnect the active torque coupling (ATC) solenoid C4347 .

Check for the following:
- corrosion (install new connector or terminals – clean module pins)
- damaged or bent pins – install new terminals/pins
- pushed-out pins – install new pins as necessary

Connect AWD Relay Module C3841 .

Connect Active Torque Coupling (ATC) solenoid C4347 and make sure it seats correctly.

PERFORM the AWD Drive Cycle.
REFER to: Four-Wheel Drive Systems - System Operation and Component Description (308-07A Four-Wheel Drive Systems, Description and Operation).
and determine if the concern is still present.

Is the concern still present?

Yes

INSTALL a new AWD relay module.
REFER to: All-Wheel Drive (AWD) Module (308-07A Four-Wheel Drive Systems, Removal and Installation).

No	The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

Description and Operation - Four-Wheel Drive Systems - System Operation and Component Description

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Removal and Installation - Brake Disc Shield

Removal

NOTE: Removal steps in this procedure may contain installation details.

Remove the brake disc.
Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
Remove the bolts and brake disc.
Torque: 80 lb.in (9 Nm)

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