Ford Explorer: Four-Wheel Drive Systems / Diagnosis and Testing - DTC Chart and Pinpoint Tests

Ford Explorer 2020-2022 Service Manual / Powertrain / Automatic Transmission / Four-Wheel Drive Systems / Diagnosis and Testing - DTC Chart and Pinpoint Tests

Diagnostic Trouble Code (DTC) 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).


  Diagnostic Trouble Code Chart


Module   DTC Description Action
  ATCM B11D9:16 Vehicle Battery: Circuit Voltage Below Threshold   GO to Pinpoint Test A
  ATCM B11D9:17 Vehicle Battery: Circuit Voltage Above Threshold   GO to Pinpoint Test A
  ATCM U0140:00 Lost Communication With Body Control Module: No Sub Type Information   GO to Pinpoint Test B
  ATCM U2002:9E Switch: Stuck On   GO to Pinpoint Test C
  ATCM U2009:9E Rotary Encoder: Stuck On   GO to Pinpoint Test D
  ATCM U3000:04 Control Module: System Internal Failure   GO to Pinpoint Test D
  AWD C00A1:57 Driveline Control Module: Invalid / Incompatible Software Component   GO to Pinpoint Test E
  AWD C00A1:F1 Driveline Control Module: <Manufacturer Defined>   GO to Pinpoint Test E
  AWD C00A5:01 Driveline Control Module Transfer Case Unit Control Circuit Driver: General Electrical Failure   GO to Pinpoint Test E
  AWD C00A5:08 Driveline Control Module Transfer Case Unit Control Circuit Driver: Bus Signal / Message Failure   GO to Pinpoint Test E
  AWD C00A5:19 Driveline Control Module Transfer Case Unit Control Circuit Drive: Circuit Current Above Threshold   GO to Pinpoint Test E
  AWD C00A5:1C Driveline Control Module Transfer Case Unit Control Circuit Driver: Circuit Voltage Out of Range   GO to Pinpoint Test E
  AWD C00A5:49 Driveline Control Module Transfer Case Unit Control Circuit Drive: Internal Electronic Failure   GO to Pinpoint Test E
  AWD C00A5:4B Driveline Control Module Transfer Case Unit Control Circuit Drive: Over Temperature   GO to Pinpoint Test E
  AWD C00A5:96 Driveline Control Module Transfer Case Unit Control Circuit Drive: Component Internal Failure   GO to Pinpoint Test E
  AWD C00A6:18 4WD/AWD Transfer Case Unit Actuator: Circuit Current Below Threshold   GO to Pinpoint Test F
  AWD C00A6:19 4WD/AWD Transfer Case Unit Actuator: Circuit Current Above Threshold   GO to Pinpoint Test F
  AWD C00A6:4B 4WD/AWD Transfer Case Unit Actuator: Over Temperature   GO to Pinpoint Test G
  AWD C00A6:54 4WD/AWD Transfer Case Unit Actuator: Missing Calibration   GO to Pinpoint Test H
  AWD C00A6:66 4WD/AWD Transfer Case Unit Actuator: Signal Has Too Many Transitions/Events   GO to Pinpoint Test I
  AWD C00A6:71 4WD/AWD Transfer Case Unit Actuator: Actuator Stuck   GO to Pinpoint Test F
  AWD C00A6:74 4WD/AWD Transfer Case Unit Actuator: Actuator Slipping   GO to Pinpoint Test F
  AWD C00A6:99 4WD/AWD Transfer Case Unit Actuator: Exceeded Learning Limit   GO to Pinpoint Test F
  AWD C00A7:11 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Short To Ground   GO to Pinpoint Test J
  AWD C00A7:13 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Open   GO to Pinpoint Test J
  AWD C00A7:17 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Voltage Above Threshold   GO to Pinpoint Test J
  AWD C00A8:11 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Short To Ground   GO to Pinpoint Test K
  AWD C00A8:13 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Open   GO to Pinpoint Test K
  AWD C00A8:17 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Voltage Above Threshold   GO to Pinpoint Test K
  AWD P0562:00 System Voltage Low: No Sub Type Information   GO to Pinpoint Test E
  AWD P0563:00 System Voltage high: No Sub Type Information   GO to Pinpoint Test E
  AWD P0603:00 Internal Control Module Keep Alive Memory (KAM) Error: No Sub Type Information   GO to Pinpoint Test E
  AWD P0604:00 Internal Control Module Random Access Memory (RAM) Error: No Sub Type Information   GO to Pinpoint Test E
  AWD P0605:00 Internal Control Module Read Only Memory (ROM) Error: No Sub Type Information   GO to Pinpoint Test E
  AWD P0607:00 Control Module Performance: No Sub Type Information   GO to Pinpoint Test E
  AWD P060A:00 Internal Control Module Monitoring Processor Performance: No Sub Type Information   GO to Pinpoint Test E
  AWD P060B:00 Internal Control Module A/D Processing Performance: No Sub Type Information   GO to Pinpoint Test E
  AWD P060C:00 Internal Control Module Main Processor Performance: No Sub Type Information   GO to Pinpoint Test E
  AWD P0630:00 VIN Not Programmed or Incompatible - ECM/PCM: No Sub Type Information   GO to Pinpoint Test L
  AWD P064F:00 Unauthorized Software/Calibration Detected: No Sub Type Information   GO to Pinpoint Test E
  AWD P068A:00 ECM/PCM Power Relay De-Energized - Too Early: No Sub Type Information   GO to Pinpoint Test E
  AWD P1001:00 KOER Not Able to Complete, KOER Aborted: No Sub Type Information   GO to Pinpoint Test M
  AWD P1397:01 System Voltage Out Of Self-Test Range: General Electrical Failure   GO to Pinpoint Test M
  AWD P1501:00 Vehicle Speed Sensor Out Of Self Test Range: No Sub Type Information   GO to Pinpoint Test M
  AWD P160A:00 Control Module Vehicle Options Reconfiguration Error: No Sub Type Information   GO to Pinpoint Test L
  AWD P166E:00 Internal control module all wheel drive discounnect control performance: No Sub Type Information   GO to Pinpoint Test N
  AWD P1674:00 Control Module Software Corrupted: No Sub Type Information   GO to Pinpoint Test E
  AWD P1705:00 Transmission Range Circuit Not Indicating Park/Neutral During Self-Test: No Sub Type Information   GO to Pinpoint Test M
  AWD U0100:00 Lost Communication With ECM/PCM "A": No Sub Type Information   GO to Pinpoint Test O
  AWD U0101:00 Lost Communication with TCM: No Sub Type Information   GO to Pinpoint Test O
  AWD U0121:00 Lost Communication With Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information   GO to Pinpoint Test O
  AWD U0126:00 Lost Communication With Steering Angle Sensor Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0137:00 Lost Communication With Trailer Brake Control Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0138:00 Lost Communication with All Terrain Control Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0140:00 Lost Communication With Body Control Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0146:00 Lost Communication With Serial Data Gateway "A": No Sub Type Information   GO to Pinpoint Test O
  AWD U0151:00 Lost Communication With Restraints Control Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0155:00 Lost Communication With Instrument Panel Cluster (IPC) Control Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0164:00 Lost Communication With HVAC Control Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0212:00 Lost Communication With Steering Column Control Module: No Sub Type Information   GO to Pinpoint Test O
  AWD U0402:00 Invalid Data Received from TCM: No Sub Type Information   GO to Pinpoint Test P
  AWD U0415:00 Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information   GO to Pinpoint Test P
  AWD U0422:00 Invalid Data Received From Body Control Module: No Sub Type Information   GO to Pinpoint Test P
  AWD U0423:00 Invalid Data Received from Instrument Panel Cluster Control Module: No Sub Type Information   GO to Pinpoint Test P
  AWD U0428:00 Invalid Data Received From Steering Angle Sensor Module: No Sub Type Information   GO to Pinpoint Test P
  AWD U1012:00 Invalid Internal Control Module Monitoring Data Received from Anti-Lock Brake System (ABS) Control Module: No Sub Type Information   GO to Pinpoint Test P
  AWD U1014:00 Invalid Internal Control Module Monitoring Data Received from Restraints Control Module: No Sub Type Information   GO to Pinpoint Test P
  AWD U2100:00 Initial Configuration Not Complete: No Sub Type Information   GO to Pinpoint Test L
  AWD U2101:00 Control Module Configuration Incompatible: No Sub Type Information   GO to Pinpoint Test L
  AWD U2200:00 Control Module Configuration Memory Corrupt: No Sub Type Information   GO to Pinpoint Test L

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.


  Global Customer Symptom Code Chart


Customer Symptom Action
Driver Aides & Information > Owner Guides/Labels > Operating Manual > Inaccurate   GO to Pinpoint Test Z
Start/Run/Move > Moving > 4 x 4 Function > Intermittent   GO to Pinpoint Test R
Start/Run/Move > Moving > 4 x 4 Function > Intermittent   GO to Pinpoint Test S
Start/Run/Move > Moving > 4 x 4 Function > Intermittent   GO to Pinpoint Test T
Start/Run/Move > Moving > 4 x 4 Function > Intermittent   GO to Pinpoint Test U
Start/Run/Move > Moving > 4 x 4 Function > Intermittent   GO to Pinpoint Test Y
Start/Run/Move > Moving > 4 x 4 Function > Intermittent   GO to Pinpoint Test AA
Start/Run/Move > Noise > Moving/Driving > Always   GO to Pinpoint Test AB
Start/Run/Move > Noise > Moving/Driving > Always   GO to Pinpoint Test AC
Driving Performance > Lack/Loss of Power > Acceleration >Always   GO to Pinpoint Test Q
Stop/Steer/Ride > Fluids > Transfer Case Fluids > Visible Leak   GO to Pinpoint Test V
Stop/Steer/Ride > Fluids > Transfer Case Fluid > Visible Leak   GO to Pinpoint Test W
Stop/Steer/Ride > Fluids > Transfer Case Fluid > Visible Leak   GO to Pinpoint Test X

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).

Condition Actions
Incorrect torque transferred to front axle after installing new transfer case   GO to Pinpoint Test Q
The AWD module does not respond to the diagnostic scan tool   REFER to: (418-00 Module Communications Network)
Communications Network - Overview (Description and Operation).
The ATCM does not respond to the diagnostic scan tool   REFER to: (418-00 Module Communications Network)
Communications Network - Overview (Description and Operation).
The transfer case does not transfer torque correctly Possible Sources: Transfer case clutch actuator position sensor faults or Transfer case clutch actuator reduction gearset binding or Transfer case clutch actuator GO to Pinpoint Test S transfer case clutch worn or damaged GO to Pinpoint Test S Wiring harness faults GO to Pinpoint Test T AWD module GO to Pinpoint Test U
Fluid leak from Transfer Case Possible Sources: Case seal GO to Pinpoint Test V Input/output shaft seals GO to Pinpoint Test W Actuator shaft seal Vent or Vent GO to Pinpoint Test X
Front axle binding on sharp turns on dry pavement   GO to Pinpoint Test Y
4WD Temporarily Locked message displayed Possible Sources: Vehicle driven in extreme terrain GO to Pinpoint Test Z Internal transfer case damage GO to Pinpoint Test AA

Symptom Chart — NVH

NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system.

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).

Condition Actions
Clicking/whirring noise from transfer case at start up   GO to Pinpoint Test AB
The transfer case makes noise Possible Sources: Internal components or Fluid level GO to Pinpoint Test AC
Noise from the front axle  
REFER to: Front Drive Axle and Differential - Vehicles Built From: 10-August-2020 (205-03 Front Drive Axle/Differential, Description and Operation).
Noise from the rear axle  
REFER to: Rear Drive Axle and Differential (205-02 Rear Drive Axle/Differential, Description and Operation).

Pinpoint Tests


PINPOINT TEST A : B11D9:16 OR B11D9:17

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

Normal Operation and Fault Conditions

If the ATCM observes an overpower or a low voltage condition, a DTC is set and all ATCM outputs are turned off.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
ATCM B11D9:16 Vehicle Battery: Circuit Voltage Below Threshold This DTC sets when the ATCM detects less than 8 volts at pin 1 for 10 seconds.
ATCM B11D9:17 Vehicle Battery: Circuit Voltage Above Threshold This DTC sets when the ATCM detects more than 17 volts at pin 1 for 10 seconds.

Possible Sources

  • Vehicle charging system issue
  • Loose connector or poor terminal pin fit
  • ATCM
A1 CHECK OTHER MODULES FOR VOLTAGE DTC (DIAGNOSTIC TROUBLE CODE)
  • Ignition ON.
  • Enter the following diagnostic mode: Run All CMDTC .

Are low or high voltage DTC present in one or more modules?
Yes For diagnosis of the battery and charging system,
REFER to: Charging System - Overview (414-00 Charging System - General Information, Description and Operation).
No GO to A2

A2 CHECK VOLTAGE AND GROUND TO THE ATCM (ALL TERRAIN CONTROL MODULE)
  • Ignition OFF.
  • Disconnect ATCM connector C3639 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Ignition ON.
  • While manipulating the harness (wiggle testing) measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3639-1   C3639-4

Is the voltage between 10 and 15 volts and remain constant while manipulating the harness?
Yes INSTALL a new ATCM.
REFER to: All Terrain Control Module (ATCM) (307-07A Four-Wheel Drive Systems, Removal and Installation).
No REPAIR the open or short circuit.

PINPOINT TEST B : LOST COMMUNICATION WITH BCM (BODY CONTROL MODULE)

Refer to Wiring Diagrams Cell 34 for schematic and connector information. Refer to Wiring Diagrams Cell 14 for schematic and connector information.

Normal Operation and Fault Conditions

The ATCM expects to receive network data from the BCM via the GWM on HS-CAN2. The ATCM will set a DTC when it has not received messages from the BCM for more than 5 seconds. Other modules that require data from the BCM may set lost communication DTC.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
ATCM U0140:00 Lost Communication With Body Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.

Possible Sources

  • Suspect module
  • Battery voltage concern
  • HS-CAN
B1 CHECK FOR LOST COMMUNICATION DTC (DIAGNOSTIC TROUBLE CODE) IN OTHER MODULES
  • Enter the following diagnostic mode: Run all CMDTC .

Do any other modules on the vehicle also have a Lost Communication DTC with the BCM?
Yes
REFER to: Communications Network - Overview (418-00 Module Communications Network, Description and Operation).
No GO to B2

B2 REVIEW CMDTC (CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE) FOR LOW VOLTAGE DTC (DIAGNOSTIC TROUBLE CODE)
  • Review all module CMDTC for low voltage DTC

Do any modules have low voltage DTC set?
Yes Resolve all vehicle voltage concerns.
REFER to: Charging System - Overview (414-00 Charging System - General Information, Description and Operation).
No GO to B3

B3 INSPECT HS-CAN (HIGH-SPEED CONTROLLER AREA NETWORK) CONNECTORS

  • Refer to Wiring Diagrams Cell 14 for schematic and connector information.
    DISCONNECT and INSPECT the HS-CAN1 and HS-CAN2 between the ATCM and the BCM.
  • Repair:
    • 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 all connectors. Make sure each connector seats and latches correctly.
  • Operate the system and verify the concern is still present.

Is the concern still present?
Yes CHECK for any applicable TSB. If a TSB exists for this concern, DISCONTINUE this test and FOLLOW TSB instructions. If no TSB address this concern, INSTALL a new BCM.
REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, 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 : U2002:9E

Normal Operation and Fault Conditions

The ATCM monitors the switch input every 10 ms. If the switch contacts are closed for an excessive amount of time, the ATCM will store a DTC. Mode selection will not be possible by pressing the button. Customer objects placed on the switch can cause this DTC to set.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
ATCM U2002:9E Switch: Stuck On Sets when the ATCM switch contacts are closed for more than 2 minutes.

Possible Sources

  • ATCM
C1 VERIFY THE CONCERN IS PRESENT
  • Ignition ON.
  • Using a diagnostic scan tool, perform the ATCM module on-demand self-test.

Did the ATCM set U2002:9E On Demand DTC?
Yes INSTALL a new ATCM.
REFER to: All Terrain Control Module (ATCM) (307-07A Four-Wheel Drive Systems, Removal and Installation).
No The system is operating correctly at this time. The concern may have be caused by an object placed on the ATCM.

PINPOINT TEST D : U2009:9E OR U3000:04

Normal Operation and Fault Conditions

The ATCM rotary encoder uses an optical sensor to determine the position and movement of the rotary dial. The ATCM monitors the optical sensor circuitry for opens and shorts. The ATCM monitors internal LED circuits, EEPROM, and application memory for faults.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
ATCM U2009:9E Rotary Encoder: Stuck On The ATCM has detected a short or open circuit for the rotary encoder optical sensor. This fault is internal to the ATCM. INSTALL a new ATCM.
REFER to: All Terrain Control Module (ATCM) (307-07A Four-Wheel Drive Systems, Removal and Installation).
ATCM U3000:04 Control Module: System Internal Failures Sets when the ATCM detects an internal failure. INSTALL a new ATCM.
REFER to: All Terrain Control Module (ATCM) (307-07A Four-Wheel Drive Systems, Removal and Installation).

Possible Sources

  • ATCM module
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST E : AWD MODULE POWER, GROUND, OR INTERNAL FAULT

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

Normal Operation and Fault Conditions

If the AWD module observes an overpower or a low voltage condition, a DTC is set.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD C00A1:57 Driveline Control Module: Invalid/Incompatible Software Component Sets when the AWD module detects invalid / incompatible software.
AWD C00A1:F1 Driveline Control Module: Manufacturer Defined Indicates the AWD module went into a safe state.
AWD C00A5:01 Driveline Control Module Transfer Case Unit Control Circuit Driver: General Electrical Failure Sets when the AWD module detects transfer Case Unit Control Circuit driver general electrical failure.
AWD C00A5:08 Driveline Control Module Transfer Case Unit Control Circuit Driver: Bus Signal/Message Failures Sets when the AWD module detects transfer Case Unit Control Circuit Driver bus signal / message failure.
AWD C00A5:19 Driveline Control Module Transfer Case Unit Control Circuit Driver: Circuit Current Above Threshold The AWD module detected a high current fault.
AWD C00A5:1C Driveline Control Module Transfer Case Unit Control Circuit Driver: Circuit Voltage Out Of Range Sets when the AWD module detects transfer case unit control circuit driver circuit voltage out of range.
AWD C00A5:49 Driveline Control Module Transfer Case Unit Control Circuit Driver: Internal Electronic Failure Sets when the AWD module detects transfer case unit control circuit driver internal electronic failure.
AWD C00A5:4B Driveline Control Module Transfer Case Unit Control Circuit Driver: Over Temperature Sets when the AWD module detects transfer case unit control circuit driver over temperature.
AWD C00A5:96 Driveline Control Module Transfer Case Unit Control Circuit Driver: Component Internal Failure Sets when the AWD module detects transfer case unit control circuit driver component internal failure.
AWD P0562:00 System Voltage Low: No Sub Type Information The AWD module detected battery voltage below 9 volts on the voltage supply input circuit.
AWD P0563:00 System Voltage High: No Sub Type Information The AWD module detected battery voltage above 16 volts on the voltage supply input circuit.
AWD P0603:00 Internal Control Module Keep Alive Memory (KAM) Error: No Sub Type Information The AWD module detected an internal fault which may have been caused by a voltage supply concern to the module.
AWD P0604:00 Internal Control Module Random Access Memory (RAM) Error: No Sub Type Information The AWD module detected an internal fault which may have been caused by a voltage supply concern to the module.
AWD P0605:00 Internal Control Module Read Only Memory (ROM) Error: No Sub Type Information The AWD module detected an internal fault which may have been caused by a voltage supply concern to the module.
AWD P0607:00 Control Module Performance: No Sub Type Information The AWD module detected an internal fault which may have been caused by a voltage supply concern to the module.
AWD P060A:00 Internal Control Module Monitoring Processor Performance: No Sub Type Information The AWD module detected an internal fault which may have been caused by a voltage supply concern to the module.
AWD P060B:00 Internal Control Module A/D Processing Performance: No Sub Type Information The AWD module detected an internal fault which may have been caused by a voltage supply concern to the module.
AWD P060C:00 Internal Control Module Main Processor Performance: No Sub Type Information The AWD module detected an internal fault which may have been caused by a voltage supply concern to the module.
AWD P064F:00 Unauthorized Software/Calibration Detected: No Sub Type Information Sets when the AWD module detects unauthorized software/calibration detected.
AWD P068A:00 ECM/PCM Power Relay De-Energized - Too Early: No Sub Type Information The AWD module detected 0 volts on the voltage supply input circuit before it was expected.
AWD P1674:00 Control Module Software Corrupted: No Sub Type Information Sets when the AWD module detects control module software corrupted.

Possible Sources

  • Vehicle level voltage concern
  • AWD module voltage supply
  • AWD module ground
  • AWD module
E1 CHECK FOR VOLTAGE DTC IN OTHER MODULES
  • Ignition ON.
  • Connect the diagnostic scan tool.
  • Retrieve continuous memory DTC.

Are voltage DTC set in other modules?
Yes
REFER to: Charging System - Overview (414-00 Charging System - General Information, Description and Operation).
No GO to E2

E2 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to E3

E3 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE POWER FOR VOLTAGE
  • Ignition OFF.
  • Disconnect the AWD module connector C3841 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Ignition ON.
  • While manipulating the harness (wiggle test) measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-1   Ground

Is the voltage greater than 10v and remain constant while wiggle testing the harness?
Yes GO to E4
No REPAIR the circuit.

E4 VERIFY CONCERN IS PRESENT
  • Ignition ON.
  • Connect the diagnostic scan tool.
  • Clear continuous memory DTC.
  • Ignition OFF.
  • Open and Close Driver’s door to initiate module shut down.
  • Wait 1 minute for AWD module to sleep.
  • Start Engine, allow to idle for 1 minute.
  • Retrieve continuous memory DTC.

Did the voltage or internal fault DTC set again?
Yes INSTALL a new AWD module.
REFER to: All-Wheel Drive (AWD) Module (307-07A Four-Wheel Drive Systems, Removal and Installation).
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 F : TRANSFER CASE CLUTCH ACTUATOR

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

Normal Operation and Fault Conditions

The transfer case clutch actuator is a reversible DC motor. When front axle torque is required, the actuator motor rotates clockwise to engage a ball-ramp device. When no torque is required, the motor rotates counter-clockwise to the kiss point position. If an AWD fault is detected, the AWD module may hold the actuator motor position, attempt full clutch release, or attempt full clutch apply.

Each time the AWD module wakes up, it will command the transfer case clutch actuator counter clockwise to the hard stop position, clockwise to the soft stop, and back to the kiss point position. If needed, it will adjust the previous kiss point position to the new learned position.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD C00A6:18 4WD/AWD Transfer Case Unit Actuator: Circuit Current Below Threshold When the AWD module commanded the transfer case actuator on, the current measured at AWD module pins 13 and 14 was less than expected. This can be caused by a shorted actuator or wire harness, or a mechanical fault in the transfer case.
AWD C00A6:19 4WD/AWD Transfer Case Unit Actuator: Circuit Current Above Threshold When the AWD module commanded the transfer case actuator on, the current measured at AWD module pins 13 and 14 was greater than expected. This can be caused by a seized actuator, a mechanical fault (seized or binding reduction gearset) in the transfer case, a short to ground in the TCMPS+ circuit, or a TCMPS+ open circuit.
AWD C00A6:71 4WD/AWD Transfer Case Unit Actuator: Actuator Stuck The AWD module was unable to learn the actuator clutch kiss point position. This can be caused by a seized actuator, a mechanical fault (seized or binding reduction gearset) in the transfer case, a short to ground in the TCMPS+ circuit, or a TCMPS+ open circuit.
AWD C00A6:74 4WD/AWD Transfer Case Unit Actuator: Actuator Slipping The AWD module was unable to learn the actuator clutch hard stop position (counter-clockwise shaft rotation).
AWD C00A6:99 4WD/AWD Transfer Case Unit Actuator: Exceeded Learning Limit The AWD module can not determine actuator position due to intermittent or conflicting transfer case actuator position sensor input.

Possible Sources

  • Transfer case clutch actuator position sensor faults
  • Loose AWD module case ground connection
  • TCMPS+, TCMC+, TCMC-, or transfer case clutch actuator shorted to ground
  • TCMPS+, TCMC+, TCMC- high resistance
  • TCMC+ and TCMC- circuits shorted together
  • Transfer case clutch actuator
  • Transfer case
F1 CHECK FOR TRANSFER CASE CLUTCH ACTUATOR POSITION SENSOR FAULTS
  • Review DTC retrieved from AWD module continuous memory self-test.

Are any transfer case clutch actuator position sensor DTC stored in memory?
Yes RESOLVE all transfer case clutch actuator position sensor DTC first.
No GO to F2

F2 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to F3

F3 CHECK THE TRANSFER CASE CLUTCH ACTUATOR (TCMPS+) AND (TCMC) CIRCUITS FOR SHORT TO GROUND
  • Disconnect the AWD module connector C3841 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Disconnect the transfer case clutch connector C350 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
    TCMPS+ C3841-35   Ground
    TCMC+ C3841-13   Ground
    TCMC- C3841-14   Ground

Are the resistances greater than 10,000 ohms?
Yes GO to F4
No REPAIR the short to ground.

F4 CHECK THE TRANSFER CASE CLUTCH ACTUATOR (TCMPS+) AND (TCMC) CIRCUITS FOR HIGH RESISTANCE
  • Disconnect the AWD module connector C3841 .
  • Disconnect the transfer case clutch actuator connector C350 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
    TCMPS+ C3841-35   C350-1
    TCMC+ C3841-13   C350-5
    TCMC- C3841-14   C350-8

Are the resistances less than 3 ohms?
Yes GO to F5
No REPAIR the open circuit.

F5 CHECK THE TRANSFER CASE CLUTCH ACTUATOR CIRCUITS FOR A SHORT TOGETHER
  • Disconnect the AWD module connector C3841 .
  • Disconnect the transfer case clutch actuator connector C350 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C350-8   C350-5

Is the resistance greater than 10,000 ohms?
Yes GO to F6
No REPAIR the short circuit.

F6 CHECK TRANSFER CASE REDUCTION GEARSET

NOTE: Do not apply more than 18  lb.in ( 2  Nm) of torque to the transfer case clutch shaft. Excessive input torque will damage the clutch hub.

  • Remove transfer case clutch actuator.
  • Manually turn transfer case clutch shaft counter-clockwise to hard stop. The shaft should rotate easily and smoothly with less than 9  lb.in ( 1  Nm) of torque.
  • Rotate actuator shaft clockwise to soft stop. It may take up to 25 turns stop to stop.The shaft should rotate easily and smoothly with less than 9  lb.in ( 1  Nm) of torque.

Does the clutch shaft hit both stop points as described?
Yes GO to F7
No INSTALL a new transfer case.
REFER to: Transfer Case (307-07B Transfer Case, Removal).
REFER to: Transfer Case (307-07B Transfer Case, Installation).

F7 CHECK TRANSFER CASE CLUTCH ACTUATOR MOTOR WINDING RESISTANCE
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 5 Component side pin 8

Is the resistance less than 100 ohms?
Yes GO to F8
No INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

F8 CHECK TRANSFER CASE CLUTCH ACTUATOR POSITION SENSOR CIRCUITS FOR SHORT TO SENSOR GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 1 Component side pin 2
    Component side pin 3 Component side pin 2
    Component side pin 4 Component side pin 2

Is the resistance greater than 1,000 ohms?
Yes GO to F9
No INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

F9 CHECK TRANSFER CASE CLUTCH ACTUATOR MOTOR AND POSITION SENSOR CIRCUITS FOR SHORT TO SENSOR GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 2 Transfer case clutch actuator housing
    Component side pin 5 Transfer case clutch actuator housing

Is the resistance greater than 1,000 ohms?
Yes GO to F10
No
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

F10 VERIFY CONCERN IS PRESENT
  • Ignition OFF.
  • Connect the AWD module C3841 .
  • Connect the transfer case clutch actuator C350 .
  • Ignition ON.
  • Connect the diagnostic scan tool.
  • Clear continuous memory DTC.
  • Ignition OFF.
  • Open and Close Driver’s door to initiate module shut down.
  • Wait 1 minute for AWD module to sleep.
  • Road test vehicle including several accelerations from a stop.
  • Retrieve continuous memory DTC.

Did the DTC set again?
Yes INSTALL a new transfer case.
REFER to: Transfer Case (307-07B Transfer Case, Removal).
No The system is operating correctly at this time.

PINPOINT TEST G : C00A6:4B

Normal Operation and Fault Conditions

The AWD logic calculates the transfer case clutch actuator motor brush temperature. If the calculated temperature exceeds the threshold, the AWD module will disable the motor for some time to allow the motor to cool down. Normal operation will return once the motor has cooled. C00A6:4B may be caused by unique driving conditions.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD C00A6:4B 4WD/AWD Transfer Case Unit Actuator: Over Temperature Sets when the AWD module logic calculates the transfer case clutch actuator motor brush temperature is too high.

Possible Sources

  • Unique driving conditions
  • Transfer case clutch actuator
G1 ATTEMPT TO DUPLICATE THE CONCERN
  • Enter the following diagnostic mode: Clear and Retest AWD module CMDTC .
  • Road test the vehicle. Perform several moderate accelerations from a stop and low speeds.
  • Enter the following diagnostic mode: AWD module CMDTC self-test.

Is C00A6:4B present?
Yes GO to G2
No The system is operating normally at this time. The concern may have been caused by unique driving conditions.

G2 CHECK TRANSFER CASE CLUTCH ACTUATOR MOTOR WINDING RESISTANCE
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 5 Component side pin 8

Is the resistance less than 100 ohms?
Yes GO to G3
No INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

G3 CHECK TRANSFER CASE CLUTCH ACTUATOR POSITION SENSOR CIRCUITS FOR SHORT TO SENSOR GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 1 Component side pin 2
    Component side pin 3 Component side pin 2
    Component side pin 4 Component side pin 2

Is the resistance greater than 1,000 ohms?
Yes GO to G4
No INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

G4 CHECK TRANSFER CASE CLUTCH ACTUATOR MOTOR AND POSITION SENSOR CIRCUITS FOR SHORT TO SENSOR GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 2 Transfer case clutch actuator housing
    Component side pin 5 Transfer case clutch actuator housing

Is the resistance greater than 1,000 ohms?
Yes GO to G5
No
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

G5 VERIFY CONCERN IS PRESENT
  • Ignition OFF.
  • Connect the AWD module C3841 .
  • Connect the transfer case clutch actuator C350 .
  • Ignition ON.
  • Connect the diagnostic scan tool.
  • Clear continuous memory DTC.
  • Ignition OFF.
  • Open and Close Driver’s door to initiate module shut down.
  • Wait 1 minute for AWD module to sleep.
  • Road test vehicle including several accelerations from a stop.
  • Retrieve continuous memory DTC.

Did the DTC set again?
Yes INSTALL a new transfer case.
REFER to: Transfer Case (307-07B Transfer Case, Removal).
No The system is operating correctly at this time.

PINPOINT TEST H : C00A6:54

Normal Operation and Fault Conditions

The transfer case clutch data should be programmed into a new AWD module during the Programmable Module Installation (PMI) routine. If the AWD modules does not have this information stored or if the stored value is corrupted, the AWD module will set C00A6:54.

The transfer case configuration data can be found on a label attached to the transfer case. To program this data into the AWD module, navigate the diagnostic scan tool: Toolbox >> AWD – Active Torque Coupling Configuration. Follow the on-screen directions to enter the data.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD C00A6:54 4WD/AWD Transfer Case Unit Actuator: Missing Calibration Sets when the transfer case configuration data is missing from the AWD module software.

Possible Sources

  • Transfer case configuration data missing or corrupted
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST I : C00A6:66

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD C00A6:66 4WD/AWD Transfer Case Unit Actuator: Signal Has Too Many Transitions/Events Each actuator position sensor sends a series of 4 signals to indicate position. DTC sets when 1 or more of the signals is intermittent or missing.

Possible Sources

  • Loose AWD module case ground
  • Transfer case clutch actuator position sensor A
  • Transfer case clutch actuator position sensor B
  • Wiring, terminals or connectors
I1 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to I2

I2 CHECK ACTUATOR POSITION SENSOR "A" POSITION SENSOR SIGNAL FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Disconnect the AWD module connector C3841 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C3841-4   C350-3

Is the resistance less than 3 ohms?
Yes GO to I3
No REPAIR the open circuit.

I3 CHECK ACTUATOR POSITION SENSOR "A" POSITION SENSOR SIGNAL FOR SHORT TO GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Disconnect the AWD module connector C3841 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C3841-4   Ground

Is the resistance greater than 10,000 ohms?
Yes GO to I4
No REPAIR the short to ground.

I4 CHECK ACTUATOR POSITION SENSOR "B" POSITION SENSOR SIGNAL FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Disconnect the AWD module connector C3841 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C3841-5   C350-4

Is the resistance less than 3 ohms?
Yes GO to I5
No REPAIR the open circuit.

I5 CHECK ACTUATOR POSITION SENSOR "B" POSITION SENSOR SIGNAL FOR SHORT TO GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Disconnect the AWD module connector C3841 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C3841-5   Ground

Is the resistance greater than 10,000 ohms?
Yes GO to I6
No REPAIR the short to ground.

I6 CHECK THE TRANSFER CASE POSITION SENSOR VOLTAGE
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Ignition ON.
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C350-1   Ground

Is the voltage between 4.7-5.3v?
Yes Proper voltage is getting to the clutch actuator position sensors. GO to I7
No REPAIR the circuit.

I7 CHECK THE TRANSFER CASE POSITION SENSOR GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Ignition ON.
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C350-1   C350-2

Is the voltage between 4.7-5.3v?
Yes The clutch actuator position sensor ground circuit is intact. GO to I8
No REPAIR the circuit.

I8 CHECK TRANSFER CASE CLUTCH ACTUATOR POSITION SENSOR CIRCUITS FOR SHORT TO SENSOR GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 1 Component side pin 2
    Component side pin 3 Component side pin 2
    Component side pin 4 Component side pin 2

Is the resistance greater than 1,000 ohms?
Yes GO to I9
No INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

I9 CHECK TRANSFER CASE CLUTCH ACTUATOR MOTOR AND POSITION SENSOR CIRCUITS FOR SHORT TO SENSOR GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator C350 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    Component side pin 2 Transfer case clutch actuator housing
    Component side pin 5 Transfer case clutch actuator housing

Is the resistance greater than 1,000 ohms?
Yes GO to I10
No
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).

I10 VERIFY CONCERN IS PRESENT
  • Ignition ON.
  • Connect the diagnostic scan tool.
  • Clear continuous memory DTC.
  • Ignition OFF.
  • Open and Close Driver’s door to initiate module shut down.
  • Wait 1 minute for AWD module to sleep.
  • Road test vehicle including several accelerations from a stop.
  • Retrieve continuous memory DTC.

Did DTC C00A6:66 set again?
Yes INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).
No The system is operating correctly at this time.

PINPOINT TEST J : C00A7:11, C00A7:13, C00A7:17

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

Normal Operation and Fault Conditions

The transfer case clutch actuator contains 2 hall effect position sensors A and B. The sensors share power (TCMPS+) and ground (TCMPS-) circuits. Power is provided by the AWD module and is 5v.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD C00A7:11 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Short To Ground This DTC sets if the AWD module detects a short to ground in the A position sensor circuit.
AWD C00A7:13 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Open This DTC sets if the AWD module detects an open in the A position sensor circuit.
AWD C00A7:17 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Voltage Above Threshold This DTC sets if the AWD module detects high voltage in the A position sensor circuit.

Possible Sources

  • Wiring, terminals or connectors
  • Transfer case clutch actuator
J1 CHECK FOR TRANSFER CASE ACTUATOR POSITION SENSOR "B" POSITION DTC
  • Review continuous DTC retrieved from the AWD module.

Was C00A8 actuator position sensor "B" DTC also retrieved from the AWD module?
Yes The sensors share the same power and signal return circuits. GO to J4
No The concern is isolated to the actuator position sensor "A" sensor signal. GO to J2

J2 CHECK ACTUATOR POSITION SENSOR "A" POSITION SENSOR SIGNAL FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Disconnect the AWD module connector C3841 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-4   C350-3

Is the resistance less than 3 ohms?
Yes GO to J3
No REPAIR the open circuit.

J3 CHECK ACTUATOR POSITION SENSOR "A" POSITION SENSOR SIGNAL FOR SHORT TO GROUND
  • Ignition OFF.
  • Disconnect the transfer case clutch actuator connector C350 .
  • Inspect harness connector for damage.
  • Disconnect the AWD module connector C3841 .
  • Inspect harness connector for damage.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-4   Ground

Is the resistance greater than 10,000 ohms?
Yes The sensor power, signal, and ground circuits are ok. INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).
No REPAIR the short to ground.

J4 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to J5

J5 CHECK THE TRANSFER CASE POSITION SENSOR VOLTAGE
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C350-1   Ground

Is the voltage between 4.7-5.3v?
Yes Voltage is present at the clutch actuator.GO to J8
No GO to J6

J6 CHECK THE TRANSFER CASE POSITION SENSOR POWER CIRCUIT FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Disconnect AWD module C3841 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-35   C350-1

Is the resistance less than 3 ohms?
Yes GO to J7
No REPAIR the open circuit.

J7 CHECK THE TRANSFER CASE POSITION SENSOR POWER CIRCUIT FOR SHORT TO GROUND
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Disconnect AWD module C3841 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-35   Ground

Is the resistance greater than 10,000 ohms?
Yes INSTALL a new AWD module.
REFER to: All-Wheel Drive (AWD) Module (307-07A Four-Wheel Drive Systems, Removal and Installation).
No REPAIR the short to ground.

J8 CHECK THE TRANSFER CASE POSITION SENSOR GROUND FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Disconnect AWD module C3841 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-18   C350-2

Is the resistance less than 3 ohms?
Yes INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).
No REPAIR the open circuit.

PINPOINT TEST K : C00A8:11, C00A8:13, C00A8:17

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

Normal Operation and Fault Conditions

The transfer case clutch actuator contains 2 hall effect position sensors A and B. The sensors share power (TCMPS+) and ground (TCMPS-) circuits. Power is provided by the AWD module and is 5v.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD C00A8:11 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Short To Ground This DTC sets if the AWD module detects a short to ground in the "B" position sensor circuit.
AWD C00A8:13 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Open This DTC sets if the AWD module detects an open in the "B" position sensor circuit.
AWD C00A8:17 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Voltage Above Threshold AWD transfer case actuator position sensor "B" circuit Voltage above threshold.

Possible Sources

  • Wiring, terminals and connectors
  • Transfer case clutch actuator
K1 CHECK FOR TRANSFER CASE ACTUATOR POSITION SENSOR "A" POSITION DTC
  • Review Continuos DTC retrieved from the AWD module.

Was C00A7 actuator position sensor "A" DTC stored?
Yes The sensors share the same power and ground circuits. GO to Pinpoint Test J
No The concern is isolated to the actuator position sensor "B" sensor signal. GO to K2

K2 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to K3

K3 CHECK ACTUATOR POSITION SENSOR "B" POSITION SENSOR SIGNAL FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case shift actuator connector C350 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Disconnect the AWD module connector C3841 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C3841-5   C350-4

Is the resistance less than 3 ohms?
Yes GO to K4
No REPAIR the open circuit.

K4 CHECK ACTUATOR POSITION SENSOR "B" POSITION SENSOR SIGNAL FOR SHORT TO GROUND
  • Ignition OFF.
  • Disconnect the transfer case shift actuator connector C350 .
  • Disconnect the AWD module connector C3841 .
  • Measure:
    Positive Lead Measurement / Action Negative Lead
      C3841-5   Ground

Is the resistance greater than 10,000 ohms?
Yes The sensor power, signal, and ground circuits are ok. Install the transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).
No REPAIR the short to ground.

PINPOINT TEST L : MODULE CONFIGURATION FAULTS

Normal Operation and Fault Conditions

A new AWD receives and saves vehicle identification (VID) block information from the PCM and BCM when the new AWD module powers up for the first time. During each subsequent module wake up, the AWD module compares the stored values to those being broadcast by the PCM and BCM. The diagnostic tool can be used to initiate a relearn procedure for the AWD module.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD P0630:00 VIN Not Programmed or Incompatible - ECM/PCM: No Sub Type Information The VIN stored in the AWD module does not match the value being passed by the PCM.
AWD P160A:00 Control Module Vehicle Options Reconfiguration Error: No Sub Type Information The VIN, tire circumference, and axle ratio that are stored in the AWD module do not match the values being passed by the BCM.
AWD U2100:00 Initial Configuration Not Complete: No Sub Type Information Sets when the AWD module detects initial configuration not complete.
AWD U2101:00 Control Module Configuration Incompatible: No Sub Type Information Sets when the AWD module detects control module configuration incompatible.
AWD U2200:00 Control Module Configuration Memory Corrupt: No Sub Type Information This DTC sets due to an internal fault with the AWD module.

Possible Sources

  • Incomplete PMI procedure on suspect module
  • Loose AWD module case ground.
  • Improper module replacement
  • AWD module
L1 CARRY OUT THE AWD (ALL-WHEEL DRIVE) - RELEARN VEHICLE DATA FUNCTION
  • Enter the following diagnostic mode: AWD - Relearn vehicle data .
  • Enter the following diagnostic mode: Clear and Retest AWD CMDTC self-test.

Did the DTC reset?
Yes GO to L2
No The repair is complete.

L2 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to L3

L3 CARRY OUT PMI (PROGRAMMABLE MODULE INSTALLATION) ON SUSPECT MODULE USING AS-BUILT DATA
  • Using a diagnostic scan tool, carry out the PMI procedure on the suspect module using As-Built data.
  • Enter the following diagnostic mode: AWD - Relearn vehicle data.
  • Enter the following diagnostic mode: Clear and Retest AWD CMDTC self-test.

Did the DTC set?
Yes INSTALL a new AWD module.
REFER to: All-Wheel Drive (AWD) Module (307-07A Four-Wheel Drive Systems, Removal and Installation).
No The repair is complete.

PINPOINT TEST M : P1001, P1397, P1501, P1705

Normal Operation and Fault Conditions

The AWD module KOER self-test is initiated when requested by the diagnostic scan tool and the engine is running. The test may set certain faults if self-test conditions are not correct at any point during the test:

  • Engine Running. Broadcast by the PCM over HS-CAN1.
  • AWD Module voltage out of normal operating parameters. Measured by AWD module at pin 1.
  • Vehicle speed is 0. Broadcast by GWM over HS-CAN1 from ABS on HS-CAN2
  • Transmission in park (P) or neutral (N). Broadcast by the PCM over HS-CAN1.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD P1001:00 KOER Not Able to Complete, KOER Aborted: No Sub Type Information The KOER self-test timed out. The test did not complete within 4-1/2 minutes.
AWD P1397:01 System Voltage Out Of Self Test Range: General Electrical Failure The AWD module voltage at pin 1 is out of range after self-test is initiated.
AWD P1501:00 Vehicle Speed Sensor Out Of Self Test Range: No Sub Type Information The vehicle speed is greater than 0 mph (0 km/h) after self-test is initiated.
AWD P1705:00 Transmission Range Circuit Not Indicating Park/Neutral During Self Test: No Sub Type Information The transmission range is not in Park or Neutral after self-test is initiated.

Possible Sources

  • KOER entry conditions not correct upon start of self-test
  • Operator changed vehicle state during self-test
  • Other vehicle system concerns that prevented self-test completion in a timely manner
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST N : P166E:00

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

Normal Operation and Fault Conditions

The AWD module constantly monitors the AWD system for malfunctions. If it is determined that a malfunction has occurred, this DTC will be set. Common causes of this DTC include:

  • AWD module not receiving HS-CAN information as expected.
  • Transfer case clutch actuator moving faster than expected.
  • Faulty AWD module.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD P166E:00 Internal Control Module All Wheel Drive Disconnect Control Performance: No Sub Type Information This DTC sets when a malfunction has been detected by the AWD module.

Possible Sources

  • AWD module ground
  • HS-CAN1 network faults
  • Transfer case clutch actuator
  • AWD module
N1 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to N2

N2 CHECK FOR NETWORK DTC (DIAGNOSTIC TROUBLE CODE)
  • Enter the diagnostic test mode: Retrieve Continuous Memory DTC from all modules.

Are there any network (Uxxxx) DTC retrieved?
Yes Resolve all network DTC.
REFER to: Communications Network - Overview (418-00 Module Communications Network, Description and Operation).
No There are no network concerns on the vehicle. GO to N3

N3 CHECK FOR TRANSFER CASE CLUTCH ACTUATOR DTC (DIAGNOSTIC TROUBLE CODE)
  • Enter the diagnostic test mode: AWD Module On-Demand Self-Test.

Did any transfer case clutch actuator DTC (C00A6, C00A7, or C00A8) set?
Yes Resolve all transfer case clutch actuator DTC first. REFER to DTC Chart.
No The transfer case clutch actuator is operating correctly. GO to N4

N4 CHECK THE FREEZE FRAME / SNAP SHOT DATA FOR P166E
  • With P166E present in the AWD module, enter the diagnostic test mode: Retrieve Continuous Memory DTC from the AWD module.
  • Expand Freeze Frame / Snapshot data for P166E.
  • Retrieve PROG_FLOWTRACE2 value. PROG_FLOWTRACE2 is an 8-digit number representing the last 4 events. Each event is recorded as a 2-digit hexadecimal number.

Did PROG_FLOWTRACE2 contain any of the following values: 78, 79, 80, 7A, 7B, 84 or 85?
Yes GO to N5
No Confirm the AWD module is at the latest software level. If the AWD module is not at the latest software level, update the AWD module and return the vehicle to the customer. If the AWD module is at the latest software level, INSTALL a new AWD Module.
REFER to: All-Wheel Drive (AWD) Module (307-07A Four-Wheel Drive Systems, Removal and Installation).

N5 CHECK THE TRANSFER CASE POSITION SENSOR VOLTAGE
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C350-1   Ground

Is the voltage between 4.7-5.3v?
Yes Voltage is present at the clutch actuator.GO to N8
No GO to N6

N6 CHECK THE TRANSFER CASE POSITION SENSOR POWER CIRCUIT FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Disconnect AWD module C3841 .
  • Inspect harness connector for damage. Verify terminals are not splayed, damaged, or pushed out of the connector.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-35   C350-1

Is the resistance less than 3 ohms?
Yes GO to N7
No REPAIR the open circuit.

N7 CHECK THE TRANSFER CASE POSITION SENSOR POWER CIRCUIT FOR SHORT TO GROUND
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Disconnect AWD module C3841 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-35   Ground

Is the resistance greater than 10,000 ohms?
Yes INSTALL a new AWD module.
REFER to: All-Wheel Drive (AWD) Module (307-07A Four-Wheel Drive Systems, Removal and Installation).
No REPAIR the short to ground.

N8 CHECK THE TRANSFER CASE POSITION SENSOR GROUND FOR OPEN
  • Ignition OFF.
  • Disconnect the transfer case connector C350 .
  • Disconnect AWD module C3841 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3841-18   C350-2

Is the resistance less than 3 ohms?
Yes INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).
No REPAIR the open circuit.

PINPOINT TEST O : LOST COMMUNICATION WITH ANOTHER MODULE

Refer to Wiring Diagrams Cell 34 for schematic and connector information. Refer to Wiring Diagrams Cell 14 for schematic and connector information.

Normal Operation and Fault Conditions

The AWD module expects to receive network data from other modules on HS-CAN1. The AWD will set a DTC when it has not received messages from a module for more than 10.5 seconds. Other modules that require data from the suspect module may set lost communication DTC.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD U0100:00 Lost Communication With ECM/PCM "A": No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0101:00 Lost Communication with TCM: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0121:00 Lost Communication With Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0126:00 Lost Communication With Steering Angle Sensor Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0137:00 Lost Communication With Trailer Brake Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0138:00 Lost Communication with All Terrain Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0140:00 Lost Communication With Body Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0146:00 Lost Communication With Serial Data Gateway "A": No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0151:00 Lost Communication With Restraints Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0155:00 Lost Communication With Instrument Panel Cluster (IPC) Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0164:00 Lost Communication With HVAC Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.
AWD U0212:00 Lost Communication With Steering Column Control Module: No Sub Type Information The AWD has not received messages from the suspect module for more than 10.5 seconds.

Possible Sources

  • Suspect module
  • Battery voltage concern
  • HS-CAN1
O1 CHECK FOR LOST COMMUNICATION DTC (DIAGNOSTIC TROUBLE CODE) IN OTHER MODULES
  • Enter the following diagnostic mode: Run all CMDTC .

Do any other modules on the vehicle also have a Lost Communication DTC with the suspect module?
Yes
REFER to: Communications Network - Overview (418-00 Module Communications Network, Description and Operation).
No GO to O2

O2 REVIEW CMDTC (CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE) FOR LOW VOLTAGE DTC (DIAGNOSTIC TROUBLE CODE)
  • Review all module CMDTC for low voltage DTC.

Do any modules have low voltage DTC set?
Yes Resolve all vehicle voltage concerns.
REFER to: Charging System - Overview (414-00 Charging System - General Information, Description and Operation).
No GO to O3

O3 INSPECT HS-CAN1 (HIGH-SPEED CONTROLLER AREA NETWORK 1) CONNECTORS

  • Refer to Wiring Diagrams Cell 14 for schematic and connector information.
    DISCONNECT and INSPECT the HS-CAN1 connectors between the AWD and the suspect module.
  • Repair:
    • 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 all connectors. Make sure each connector seats and latches correctly.
  • Operate the system and verify the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable TSB. If a TSB exists for this concern, DISCONTINUE this test and FOLLOW TSB instructions. If no TSB address this concern, INSTALL a new suspect module.
For U0100,
   Click here to access Guided Routine (PCM). Internet Explorer version 11 or greater is required to perform this Pinpoint Test. For U0155,
   Click here to access Guided Routine (IPC). Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
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 P : INVALID DATA RECEIVED FROM ANOTHER MODULE

Normal Operation and Fault Conditions

The AWD module expects to receive network data from other modules on HS-CAN1. The AWD will set a DTC when it receives an invalid or incomplete messages from another module. Incomplete or corrupted messages typically result from high network traffic preventing the complete message from being received within the calibrated time limit.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
AWD U0402:00 Invalid Data Received from TCM: No Sub Type Information Sets when the AWD module received a message from the suspect, but the message was not complete.
AWD U0415:00 Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information Sets when the AWD module received a message from the suspect, but the message was not complete.
AWD U0422:00 Invalid Data Received From Body Control Module: No Sub Type Information Sets when the AWD module received a message from the suspect, but the message was not complete.
AWD U0423:00 Invalid Data Received from Instrument Panel Cluster Control Module: No Sub Type Information Sets when the AWD module received a message from the suspect, but the message was not complete.
AWD U0428:00 Invalid Data Received From Steering Angle Sensor Module: No Sub Type Information Sets when the AWD module received a message from the suspect, but the message was not complete.
AWD U1012:00 Invalid Internal Control Module Monitoring Data Received from Anti-Lock Brake System (ABS) Control Module: No Sub Type Information Sets when the AWD module received a message from the suspect, but the message was not complete.
AWD U1014:00 Invalid Internal Control Module Monitoring Data Received from Restraints Control Module: No Sub Type Information Sets when the AWD module received a message from the suspect, but the message was not complete.

Possible Sources

  • High network traffic event
  • Intermittent network connection
  • Suspect module
  • AWD module
P1 ATTEMPT TO DUPLICATE THE DTC (DIAGNOSTIC TROUBLE CODE)
  • Enter the following diagnostic mode: Clear and Retest the AWD CMDTC self-test.
  • Road test the vehicle.
  • Enter the following diagnostic mode: AWD module CMDTC self-test.

Did the invalid data DTC set again?
Yes For U1012:00 and U1014:00, GO to P2
For all other DTC, GO to P3
No The system is operating correctly at this time. The concern may have been caused by a high network traffic event.

P2 CHECK THE AWD (ALL-WHEEL DRIVE) MODULE GROUND
  • Ignition OFF.
  • Verify AWD module retaining nuts are secure. Torque: 55 lb. in (6.2 Nm)

Were any of the fasteners loose?
Yes TIGHTEN the AWD module nuts to specification. RETEST the system for normal operation.
No GO to P3

P3 INSPECT HS-CAN1 (HIGH-SPEED CONTROLLER AREA NETWORK 1) CONNECTORS

  • Refer to Wiring Diagrams Cell 14 for schematic and connector information.
    DISCONNECT and INSPECT the HS-CAN1 connectors between the AWD and the suspect module.
  • Repair:
    • 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 all connectors. Make sure each connector seats and latches correctly.
  • Operate the system and verify the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable TSB. If a TSB exists for this concern, DISCONTINUE this test and FOLLOW TSB instructions. If no TSB address this concern, INSTALL a new suspect module.
For U0423,
   Click here to access Guided Routine (IPC). Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
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 Q : INCORRECT TORQUE TRANSFERRED TO FRONT AXLE AFTER INSTALLING TRANSFER CASE

Normal Operation and Fault Conditions

The transfer case clutch actuator is a reversible DC motor. When front axle torque is required, the actuator motor rotates clockwise to engage a ball-ramp device. When no torque is required, the motor rotates counter-clockwise to the kiss point position. If a 4WD fault is detected, the AWD module may hold the actuator motor position, attempt full clutch release, or attempt full clutch apply.

Each time the AWD module wakes up, it will command the transfer case clutch actuator AWD clockwise to the hard stop position, clockwise to the soft stop, and back to the kiss point position. If needed, the AWD module will adjust the previous kiss point position to the new learned position. Each adjustment is limited to .3 degrees.

When a new transfer case is installed, the AWD module needs to learn the new kiss point. Carry out the Transfer Case Clutch Learn procedure. REFER to: Transfer Case Clutch Learn (307-07A Four-Wheel Drive Systems, General Procedures).

Possible Sources

  • Different kiss point position in new transfer case.
  • Intermittent network connection
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST R : THE TRANSFER CASE DOES NOT TRANSFER TORQUE CORRECTLY

Normal Operation and Fault Conditions

The transfer case clutch actuator is a reversible DC motor. When front axle torque is required, the actuator motor rotates clockwise to engage a ball-ramp device. When no torque is required, the motor rotates counter-clockwise to the kiss point position.

The transfer case clutch actuator operates with a maximum torque output of 1 Nm (8 in-lb). A 40:1 reduction gearset allows for precise and consistent clutch application force. Any binding or roughness in the reduction gearset can prevent the clutch from applying properly.

Possible Sources

  • Transfer case clutch actuator position sensor faults
  • Transfer case clutch actuator reduction gearset binding
  • Transfer case clutch actuator
R1 CHECK FOR TRANSFER CASE CLUTCH ACTUATOR POSITION SENSOR FAULTS
  • Review DTC retrieved from AWD module continuous memory self-test.

Are any transfer case clutch actuator position sensor DTC stored in memory?
Yes RESOLVE all transfer case clutch actuator position sensor DTC first.
No GO to R2

R2 CHECK TRANSFER CASE REDUCTION GEARSET

NOTE: Do not apply more than 18  lb.in ( 2  Nm) of torque to the transfer case clutch shaft. Excessive input torque will damage the clutch hub.

  • Remove transfer case clutch actuator.
  • Using a 6mm hex key, manually rotate the transfer case clutch shaft counter-clockwise to hard stop. The shaft should rotate easily and smoothly with less than 9  lb.in ( 1  Nm) of torque.
  • Rotate actuator shaft clockwise to soft stop. It may take up to 25 turns stop to stop. The shaft should rotate easily and smoothly with less than 9  lb.in ( 1  Nm) of torque.

Does the transfer case clutch shaft rotate easily and smoothly and hit both stop points as described?
Yes The transfer case reduction gearset and ball ramp are working as designed. INSTALL a new transfer case clutch actuator.
REFER to: Transfer Case Clutch Actuator (307-07A Four-Wheel Drive Systems, Removal and Installation).
No INSTALL a new transfer case.
REFER to: Transfer Case (307-07B Transfer Case, Removal).
REFER to: Transfer Case (307-07B Transfer Case, Installation).

PINPOINT TEST S : THE TRANSFER CASE DOES NOT TRANSFER TORQUE CORRECTLY

Normal Operation and Fault Conditions

The transfer case clutch is a multi-disc friction clutch used to transfer torque to the front driveline. When front axle torque is required, the actuator motor rotates clockwise to engage a ball-ramp device. When no torque is required, the motor rotates counter-clockwise to the kiss point position. If a the clutch is worn or damaged, INSTALL a new transfer case.

REFER to: Transfer Case (307-07B Transfer Case, Removal).
REFER to: Transfer Case (307-07B Transfer Case, Installation).

Possible Sources

  • Transfer case clutch worn or damaged.
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST T : THE TRANSFER CASE DOES NOT TRANSFER TORQUE CORRECTLY

Normal Operation and Fault Conditions

DIAGNOSE and REPAIR all AWD System DTC

Possible Sources

  • Wiring harness faults
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST U : THE TRANSFER CASE DOES NOT TRANSFER TORQUE CORRECTLY

Normal Operation and Fault Conditions

DIAGNOSE and REPAIR all AWD System DTC

Possible Sources

  • AWD module
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST V : FLUID LEAK FROM TRANSFER CASE

Normal Operation and Fault Conditions

Replace Transfer Case.REFER to: Transfer Case (307-07B Transfer Case, Removal).
REFER to: Transfer Case (307-07B Transfer Case, Installation).

Possible Sources

  • Case seal
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST W : FLUID LEAK FROM TRANSFER CASE

Normal Operation and Fault Conditions

Replace seals.

Possible Sources

  • Input/output shaft seals
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST X : FLUID LEAK FROM TRANSFER CASE

Normal Operation and Fault Conditions

Verify vent routing is correct, check/adjust fluid level

Possible Sources

  • Actuator shaft seal Vent
  • Vent
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST Y : FRONT AXLE BINDING ON SHARP TURNS ON DRY PAVEMENT

Normal Operation and Fault Conditions

Normal operation for Deep Snow/Sand and Slippery drive modes is to engage the transfer case. Compare to similar vehicle.

Possible Sources

  • Incorrect Drive Mode for driving conditions
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST Z : 4WD TEMPORARILY LOCKED MESSAGE DISPLAYED

Normal Operation and Fault Conditions

Refer to Owners guide.

Possible Sources

  • Vehicle driven in extreme terrain
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST AA : 4WD TEMPORARILY LOCKED MESSAGE DISPLAYED

Normal Operation and Fault Conditions

If message is displayed under normal driving conditions, REPLACE Transfer Case. REFER to: Transfer Case (307-07B Transfer Case, Removal).
REFER to: Transfer Case (307-07B Transfer Case, Installation).

Possible Sources

  • Internal transfer case damage
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST AB : CLICKING/WHIRRING NOISE FROM TRANSFER CASE AT START UP

Normal Operation and Fault Conditions

The transfer case learns the actuator clutch KISS point at each key on cycle. A certain amount of clicking/whirring noise may be normal. Compare to a similar vehicle.

Possible Sources

  • Actuator gearset and ball ramp movement
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PINPOINT TEST AC : THE TRANSFER CASE MAKES NOISE

Normal Operation and Fault Conditions

Using the diagnostic equipment, isolate noise to the transfer case.

CHECK that the transfer case is filled to the correct level and with the specified fluid. REFER to: Transfer Case Fluid Level Check (307-07B Transfer Case, General Procedures).

If fluid level is OK, INSTALL a NEW Transfer Case. REFER to: Transfer Case (307-07B Transfer Case, Removal).
REFER to: Transfer Case (307-07B Transfer Case, Installation).

Possible Sources

  • Internal components
  • Fluid level
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

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

    System Operation Principles of Operation The 4WD system is active all the time and requires no input from the driver. The 4WD system continuously monitors vehicle conditions and automatically ap..

    General Procedures - Transfer Case Clutch Learn

    Activation Update the AWD (all-wheel drive) module to the latest calibration available. Module reprogramming will erase stored transfer case clutch kiss point values and initiate rapid kiss..

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