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Home >> Mercury >> 2008 >> Milan Base, 2.3 Z, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1359 (Transfer Case - Four-Wheel Drive (4WD) System - Diagnostics) >> Diagnosis And Testing >> Four Wheel Drive (4WD) Systems >> Pinpoint Tests >> Pinpoint Test D: DTCs P1824/P1825 - 4-Wheel Drive Clutch Relay Circuit Failure/4-Wheel Drive Clutch Relay Open Circuit or Inadequate Torque at Rear Wheels >> PINPOINT TEST D: DTCs P1824/P1825 - 4-WHEEL DRIVE CLUTCH RELAY CIRCUIT FAILURE/4-WHEEL DRIVE CLUTCH RELAY OPEN CIRCUIT OR INADEQUATE TORQUE AT REAR WHEELS

PINPOINT TEST D: DTCs P1824/P1825 - 4-WHEEL DRIVE CLUTCH RELAY CIRCUIT FAILURE/4-WHEEL DRIVE CLUTCH RELAY OPEN CIRCUIT OR INADEQUATE TORQUE AT REAR WHEELS

WARNING: This page is about a different car, the 2009 Mercury Milan, 2009 Lincoln MKZ, and 2009 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Carry out a thorough inspection and verification as outlined before carrying out this pinpoint test.
  1. D1 CHECK FOR 4X4 CONTROL MODULE DTCs 
    • Key in ON position.
    • Carry out the 4X4 control module self-test.
    • Are any DTCs received? 
    1. YES  : For DTC P1824 or P1825, go to  D2.

      For all other DTCs, REFER to the DTC CHARTS .

    2. NO  : Go to  D2.
  2. D2 CHECK CIRCUITS CCF21 (VT/WH) AND RCF21 (WH/VT) FOR A SHORT TO GROUND WITH ATC SOLENOID (PART OF REAR AXLE) CONNECTED 
    • Key in OFF position.
    • Disconnect: 4X4 Control Module C3253
    • Measure the resistance between 4X4 control module C3253-8, circuit CCF21 (VT/WH), harness side and ground; and between 4X4 control module C3253-16, circuit RCF21 (WH/VT), harness side and ground.
      • Fig 1: Checking Circuits CCF21 (VT/WH) & RCF21 (WH/VT) For A Short To Ground With ATC Solenoid Connected
      GF0041483Courtesy of FORD MOTOR CO.
    • Are the resistances greater than 10,000 ohms? 
    1. YES  : Go to  D5.
    2. NO  : Go to  D3.
  3. D3 CHECK CIRCUITS CCF21 (VT/WH) AND RCF21 (WH/VT) FOR A SHORT TO GROUND WITH C3051 DISCONNECTED 
    • Disconnect: ATC Solenoid Jumper Harness C3051
    • Measure the resistance between 4X4 control module C3253-8, circuit CCF21 (VT/WH), harness side and ground; and between 4X4 control module C3253-16, circuit RCF21 (WH/VT), harness side and ground.
      • Fig 2: Checking Circuits CCF21 (VT/WH) & RCF21 (WH/VT) For A Short To Ground With C3051 Disconnected
      GF0041483Courtesy of FORD MOTOR CO.
    • Are the resistances greater than 10,000 ohms? 
    1. YES  : Go to  D4.
    2. NO  : REPAIR the circuit(s) in question. CLEAR the DTCs. REPEAT the self-test.
  4. D4 CHECKING THE ATC SOLENOID JUMPER HARNESS 
    NOTE: The ATC solenoid jumper harness must be secured to prevent damage to the wiring.
    • Disconnect: ATC Solenoid C3254
    • Inspect the ATC solenoid jumper harness for damage.
    • Is the ATC solenoid jumper harness damaged? 
    1. YES  : REPAIR or INSTALL a new ATC solenoid jumper harness. CLEAR the DTCs. REPEAT the self-test.
    2. NO  : INSTALL a new rear axle assembly. REFER to REAR DRIVE AXLE/DIFFERENTIAL article. CLEAR the DTCs. REPEAT the self-test.
  5. D5 CHECK CIRCUITS CCF21 (VT/WH) AND RCF21 (WH/VT) FOR AN OPEN WITH ATC SOLENOID CONNECTED 
    • Connect: ATC Solenoid C3254 and ATC Solenoid Jumper Harness C3051
    • Measure the resistance between 4X4 control module C3253-8, circuit CCF21 (VT/WH), harness side and 4X4 control module C3253-16, circuit RCF21 (WH/VT), harness side.
      • Fig 3: Checking Circuits CCF21 (VT/WH) & RCF21 (WH/VT) For An Open With ATC Solenoid Connected
      GF0041484Courtesy of FORD MOTOR CO.
    • Is the resistance less than 10 ohms? 
    1. YES  : Go to  D8.
    2. NO  : Go to  D6.
  6. D6 CHECK CIRCUITS CCF21 (VT/WH) AND RCF21 (WH/VT) FOR AN OPEN AT C3051 
    • Disconnect: ATC Solenoid Jumper Harness C3051
    • Measure the resistance between 4X4 control module C3253-8, circuit CCF21 (VT/WH), harness side and ATC solenoid jumper harness C3051-1, circuit CCF21 (VT/WH).
      • Fig 4: Checking Circuits CCF21 (VT/WH) & RCF21 (WH/VT) For An Open At C3051
      GF0030115Courtesy of FORD MOTOR CO.
    • Repeat this measurement while wiggling the harness.
    • Measure the resistance between 4X4 control module C3253-16, circuit RCF21 (WH/VT), harness side and ATC solenoid jumper harness C3051-2, circuit RCF21 (WH/VT), harness side.
      • Fig 5: Measuring Resistance Between 4X4 Control Module C3253-8, Circuit CCF21 (VT/WH)
      GF0030116Courtesy of FORD MOTOR CO.
    • Repeat this measurement while wiggling the harness.
    • Are the resistances less than 5 ohms? 
    1. YES  : Go to  D7.
    2. NO  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.
  7. D7 CHECK THE ATC SOLENOID CIRCUIT FOR AN INTERNAL OPEN 
    NOTE: The ATC solenoid jumper harness must be secured to prevent damage to the wiring.
    • Disconnect: ATC Solenoid C3254
    • Measure the resistance between ATC solenoid C3254-1, circuit CCF21 (VT/WH), component side, and ATC solenoid C3254-2, circuit RCF21 (WH/VT), component side.
      • Fig 6: Checking ATC Solenoid Circuit For An Internal Open
      GF0041485Courtesy of FORD MOTOR CO.
    • Repeat this measurement while wiggling the harness.
    • Is the resistance less than 10 ohms? 
    1. YES  : REPAIR or INSTALL a new ATC solenoid jumper harness. CLEAR the DTCs. REPEAT the self-test.
    2. NO  : INSTALL a new rear axle assembly. REFER to REAR DRIVE AXLE/DIFFERENTIAL article. CLEAR the DTCs. REPEAT the self-test.
  8. D8 CHECK CIRCUIT GD126 (BK/WH) FOR AN OPEN 
    • Measure the resistance between 4X4 control module C3253-15, circuit GD126 (BK/WH), harness side and ground.
      • Fig 7: Checking Circuit GD126 (BK/WH) For An Open
      GF0041481Courtesy of FORD MOTOR CO.
    • Repeat this measurement while wiggling the harness.
    • Is the resistance less than 5 ohms? 
    1. YES  : Go to  D9.
    2. NO  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  9. D9 CHECK THE 4X4 CONTROL MODULE POWER CIRCUITS 
    • Key in ON position.
    • Measure the voltage between 4X4 control module C3253-6, circuit SBP15 (WH/RD), harness side and ground; and between 4X4 control module C3253-5, circuit CBP19 (BN/WH), harness side and ground.
      • Fig 8: Checking 4X4 Control Module Power Circuits
      GF0041482Courtesy of FORD MOTOR CO.
    • Are the voltages greater than 10 volts? 
    1. YES  : Go to  D10.
    2. NO  : CHECK Smart Junction Box (SJB) fuses 20 (7.5A) and 28 (10A). REPAIR the circuit in question for open or short to ground. CLEAR the DTCs. REPEAT the self-test.
  10. D10 CHECK FOR CORRECT 4X4 CONTROL MODULE OPERATION 
    • Disconnect: 4X4 Control Module C3253
    • Check the harness and component side connectors for:
      • corrosion.
      • pushed-out/bent pins.
    • Check the ATC solenoid jumper harness between the 4X4 control module and the ATC solenoid, located on the rear subframe.
    • Connect the 4X4 control module and make sure it seats correctly.
    • Operate the system and determine if the concern is still present.
    • Is the concern still present? 
    1. YES  : INSTALL a new 4X4 control module. REFER to 4X4 CONTROL MODULE . CLEAR the DTCs. REPEAT the self-test.
    2. NO  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
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