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Home >> Mercury >> 2008 >> Milan Base, 3.0 1, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 52 (Four-Wheel Drive Systems (ESOF) - F250-F550 Super Duty) >> Diagnosis And Testing >> Four-Wheel Drive Systems - Electronic Shift >> Pinpoint Tests - Electronic Shift >> Pinpoint Test E: The Vehicle Does Not Shift Between 2WD And 4WD Correctly

Pinpoint Test E: The Vehicle Does Not Shift Between 2WD And 4WD Correctly

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. E1 CHECK THE IGNITION STATES - MONITOR THE 4WD CONTROL MODULE IGNITION PIDS 
      NOTE: If the vehicle is equipped with a manual transmission, depress the clutch pedal while turning the ignition switch to the START position.
    • Monitor the 4WD control module ignition switch PIDs while turning the ignition switch through all positions.
      IGNITION SWITCH POSITIONS AND EXPECTED VALUES

      Ignition Switch Position PID Expected Value
      OFF IGN_O/L OFF
      ACCESSORY IGN_ACC ACCY
      RUN IGN_R RUN
      START IGN_S START
    • Do the PID values agree with the ignition switch positions? 
  2. E2 RETRIEVE THE DIAGNOSTIC TROUBLE CODES (DTCS) 
    • Enter the following diagnostic mode on the scan tool: 4WD Control Module Self-Test.
    • Are any DTCs retrieved? 
    • Yes  : If DTC P1812, GO to  E4.

      If DTC P1815, GO to  E4.

      If DTC P1820, GO to  E12.

      If DTC P1822, GO to  E12.

      If DTC P1828, GO to  E19.

      If DTC P1830, GO to  E19.

      If DTC P1865, GO to  E36.

      If DTC P1867, GO to  E31.

      If DTC P1820 and P1828 are retrieved together, GO to  E26.

    • No  : GO to E3.
  3. E3 VERIFY THAT THE ELECTRONIC SHIFT FUNCTION TEST HAS BEEN CARRIED OUT 
    • Verify that the electronic shift function test has been carried out.
    • Was the electronic shift function test carried out? 
  4. E4 CHECK THE MODE SELECT SWITCH (MSS) - MONITOR THE 4WD CONTROL MODULE PID 4WD_SW 
    • Key in ON position.
    • Monitor the 4WD control module PID 4WD_SW while cycling the MSS through 2WD, 4x4 and 4x4 LOW.
    • Do the 4WD control module PID values agree with the MSS switch positions? 
    • Yes  : GO to  E10.
    • No  : GO to E5.
  5. E5 CHECK THE MSS - ALL POSITIONS 
    • Disconnect: MSS C284.
    • Measure the resistance between MSS terminal 2 and terminal 3 (component side). Refer to the following chart:
      MSS POSITION - RESISTANCE

      MSS Position Resistance
      2WD 619 ohms
      4x4 270 ohms
      4x4 LOW 130 ohms
      Fig 1: Measuring Resistance Between MSS Terminal 2 And Terminal 3
      G03923727Courtesy of FORD MOTOR CO.
    • Are the resistances within the specified values? 
    • Yes  : GO to E6.
    • No  : INSTALL a new MSS. REFER to MODE SELECT SWITCH (MSS)  in this section. CLEAR the DTCs. REPEAT the self-test.
  6. E6 CHECK CIRCUIT 465 (WH/LB) FOR AN OPEN 
    • Disconnect: 4WD Control Module C281b.
    • Measure the resistance between MSS C284 pin 2, circuit 465 (WH/LB), harness side and 4WD control module C281b pin 9, circuit 465 (WH/LB), harness side.
      Fig 2: Measuring Resistance Between MSS C284 Pin 2 And 4WD Control Module C281B Pin 9
      G03923728Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to E7.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  7. E7 CHECK CIRCUIT 780 (DB) FOR A SHORT TO VOLTAGE 
    • Key in ON position.
    • Measure the voltage between 4WD control module C281b pin 2, circuit 780 (DB), harness side and ground.
      Fig 3: Measuring Voltage Between 4WD Control Module C281B Pin 2, Circuit 780 (DB), Harness Side And Ground
      G03909533Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E8.
  8. E8 CHECK CIRCUIT 780 (DB) FOR AN OPEN 
    • Key in OFF position.
    • Measure the resistance between MSS C284 pin 3, circuit 780 (DB), harness side and 4WD control module C281b pin 2, circuit 780 (DB), harness side.
      Fig 4: Measuring Resistance Between MSS C284 Pin 3 And 4Wd Control Module C281B Pin 2
      G03923730Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to E9.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  9. E9 CHECK CIRCUIT 780 (DB) FOR A SHORT TO GROUND 
    • Measure the resistance between 4WD control module C281b pin 2, circuit 780 (DB), harness side and ground.
      Fig 5: Measuring Resistance Between 4WD Control Module C281B Pin 2, Circuit 780 (DB), Harness Side And Ground
      G03909535Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to  E57.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  10. E10 CHECK THE VOLTAGE TO THE GEARMOTOR ENCODER ASSEMBLY 
    • Disconnect: Gearmotor Encoder Assembly C350b.
      • NOTE: Voltage is only applied to the transfer case assembly for six seconds while the 4WD control module active command CW/CCW is ON.
      Fig 6: Checking The Voltage To The Gearmotor Encoder Assembly
      G03909536Courtesy of FORD MOTOR CO.
    • Measure the voltage between gearmotor encoder assembly C350b, circuit 778 (OG), harness side and ground while triggering the 4WD control module active command CW/CCW to ON; and between gearmotor encoder assembly C350a, circuit 777 (YE), harness side and ground while triggering the 4WD control module active command CW/CCW to ON.
    • Are the voltages greater than 10 volts? 
    • Yes  : GO to E11.
    • No  : If there is no voltage on circuits 777 (YE) and 778 (OG), GO to  E26.

      If there is no voltage on circuit 777 (YE) only, GO to  E12.

      If there is no voltage on circuit 778 (OG) only, GO to  E12.

  11. E11 CHECK THE VOLTAGE TO THE GEARMOTOR ENCODER ASSEMBLY 
    • Measure the voltage between gearmotor encoder assembly C350b, circuit 777 (YE), harness side and ground while triggering the 4WD control module active command CW/CCW to OFF; and between gearmotor encoder assembly C350b, circuit 778 (OG), harness side and ground while triggering the 4WD control module active command CW/CCW to OFF.
      Fig 7: Checking The Voltage To The Gearmotor Encoder Assembly
      G03909536Courtesy of FORD MOTOR CO.
    • Are the voltages greater than 10 volts? 
    • Yes  : GO to  E56.
    • No  : GO to  E31.
  12. E12 CHECK THE VOLTAGE TO THE GEARMOTOR ENCODER ASSEMBLY LOW-TO-HIGH SHIFT RELAY - CIRCUIT 704 (DG/LG) 
    • Disconnect: Gearmotor Encoder Assembly Low-to-High Relay C1129.
    • Key in ON position.
    • Measure the voltage between gearmotor encoder assembly low-to-high relay C1129 pin 86, circuit 704 (DG/LG), harness side and ground; and between gearmotor encoder assembly low to high relay C1129 pin 87, circuit 704 (DG/LG), harness side and ground.
    • Are the voltages greater than 10 volts? 
    • Yes  : GO to E13.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  13. E13 CHECK THE GEARMOTOR ENCODER ASSEMBLY LOW-TO-HIGH RELAY 
    • Key in OFF position.
    • Carry out the relay component test on the gearmotor encoder assembly low-to-high relay. Refer to COMPONENT TESTING .
    • Is the relay OK? 
    • Yes  : GO to E14.
    • No  : INSTALL a new gearmotor encoder assembly low-to-high relay. CLEAR the DTCs. REPEAT the self-test.
  14. E14 CHECK CIRCUIT 782 (BR/WH) FOR A SHORT TO VOLTAGE 
    • Disconnect: 4WD Control Module C281b.
    • Key in ON position.
    • Measure the voltage between gearmotor encoder assembly low-to-high C1129 shift relay connector pin 85, circuit 782 (BR/WH), harness side and ground.
      Fig 8: Measuring Voltage Between C1129 Shift Relay Connector Pin 85 And Ground
      G03909539Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E15.
  15. E15 CHECK CIRCUIT 782 (BR/WH) FOR AN OPEN 
    • Key in OFF position.
    • Measure the resistance between gearmotor encoder assembly low-to-high shift relay C1129 pin 85, circuit 782 (BR/WH), harness side and 4WD control module C281b pin 5, circuit 782 (BR/WH), harness side.
      Fig 9: Checking Circuit 782 (BR/WH) For An Open
      G03909540Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to E16.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  16. E16 CHECK CIRCUIT 782 (BR/WH) FOR A SHORT TO GROUND 
    • Measure the resistance between gearmotor encoder assembly low-to-high shift relay C1129 pin 85, circuit 782 (BR/WH), harness side and ground.
      Fig 10: Measuring Resistance Between C1129 Pin 85 And Ground
      G03909541Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to E17.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  17. E17 CHECK CIRCUIT 57 (BK) FOR AN OPEN 
    • Measure the resistance between gearmotor encoder assembly low-to-high shift relay C1129 pin 87A, circuit 57 (BK), harness side and ground.
      Fig 11: Measuring Resistance Between C1129 Pin 87A And Ground
      G03909542Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to E18.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  18. E18 CHECK CIRCUIT 777 (YE) FOR AN OPEN 
    • Disconnect: Gearmotor Encoder Assembly C350b.
    • Measure the resistance between gearmotor encoder assembly low-to-high relay C1129 pin 30, circuit 777 (YE), harness side and gearmotor encoder assembly C350b, circuit 777 (YE), harness side.
      Fig 12: Checking Circuit 777 (YE) For An Open
      G03909543Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E57.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  19. E19 CHECK THE VOLTAGE TO THE GEARMOTOR ENCODER ASSEMBLY HIGH-TO-LOW RELAY 
    • Remove the gearmotor encoder assembly high-to-low shift relay.
    • Key in ON position.
    • Measure the voltage between gearmotor encoder assembly high-to-low shift relay C1173 pin 85, circuit 704 (DG/LG), harness side and ground; and between gearmotor encoder assembly high-to-low shift relay C1173 pin 87, circuit 704 (DG/LG), harness side and ground.
      Fig 13: Checking The Voltage To The Gearmotor Encoder Assembly High-To-Low Relay
      G03909544Courtesy of FORD MOTOR CO.
    • Are the voltages greater than 10 volts? 
    • Yes  : GO to E20.
    • No  : REPAIR the circuit. TEST the system for normal operation.
  20. E20 CHECK THE GEARMOTOR ENCODER ASSEMBLY HIGH-TO-LOW RELAY 
    • Carry out the relay component test on the gearmotor encoder assembly high-to-low relay. Refer to COMPONENT TESTING .
    • Is the relay OK? 
    • Yes  : GO to E21.
    • No  : INSTALL a new gearmotor encoder assembly high-to-low relay. CLEAR the DTCs. REPEAT the self-test.
  21. E21 CHECK CIRCUIT 781 (OG/LB) FOR A SHORT TO VOLTAGE 
    • Disconnect: 4WD Control Module C281b.
    • Key in ON position.
    • Measure the voltage between gearmotor encoder assembly high-to-low shift relay C1173 pin 86, circuit 781 (OG/LB), harness side and ground.
      Fig 14: Checking Circuit 781 (OG/LB) For Short To Voltage
      G03909545Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E22.
  22. E22 CHECK CIRCUIT 781 (OG/LB) FOR AN OPEN 
    • Key in OFF position.
    • Measure the resistance between gearmotor encoder assembly high-to-low shift relay C1173 pin 86, circuit 781 (OG/LB), harness side and 4WD control module C281b pin 6, circuit 781 (OG/LB), harness side.
      Fig 15: Checking Circuit 781 (OG/LB) For Open
      G03909546Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to E23.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  23. E23 CHECK CIRCUIT 781 (OG/LB) FOR A SHORT TO GROUND 
    • Measure the resistance between gearmotor encoder assembly high-to-low shift relay C1173 pin 86, circuit 781 (OG/LB), harness side and ground.
      Fig 16: Checking Circuit 781 (OG/LB) For Short To Ground
      G03909547Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to E24.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  24. E24 CHECK HIGH TO LOW RELAY CIRCUIT 57 (BK) FOR AN OPEN 
    • Measure the resistance between gearmotor encoder assembly high-to-low shift relay C1173 pin 87A, circuit 57 (BK), harness side and ground.
      Fig 17: Checking High To Low Relay Circuit 57 (BK) For Open
      G03909548Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to E25.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  25. E25 CHECK CIRCUIT 778 (OG) FOR AN OPEN 
    • Measure the resistance between gearmotor encoder assembly high-to-low shift relay C1173 pin 30, circuit 778 (OG), harness side and gearmotor encoder assembly C350b, circuit 778 (OG), harness side.
      Fig 18: Checking Circuit 778 (OG) For Open
      G03909549Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E57.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  26. E26 CHECK BATTERY JUNCTION BOX (BJB) FUSE 
    • Remove the BJB fuse 3 (30A).
    • Is the BJB fuse OK? 
    • Yes  : GO to E27.
    • No  : GO to  E28.
  27. E27 CHECK VOLTAGE AT BJB FUSE 
    • Measure the voltage between BJB fuse 3 (30A) input terminal and ground.
    • Is the voltage greater than 10 volts? 
    • Yes  : REPAIR circuit 704 (DG/LG). CLEAR the DTCs. REPEAT the self-test.
    • No  : REPAIR or install a new BJB as necessary. CLEAR the DTCs. REPEAT the self-test.
  28. E28 CHECK CIRCUIT 704 (DG/LG) FOR A SHORT TO GROUND 
    • Remove the gearmotor encoder assembly high-to-low shift relay.
    • Remove the gearmotor encoder assembly low-to-high shift relay.
    • Measure the resistance between gearmotor encoder assembly high-to-low shift relay C1173 pin 85, circuit 704 (DG/LG), harness side and ground; and between gearmotor encoder assembly low-to-high shift relay C1129 pin 85, circuit 704 (DG/LG), harness side and ground.
    • Is the resistance less than 5 ohms? 
    • Yes  : REPAIR the supply circuit. INSTALL a new CJB fuse. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E29.
  29. E29 CHECK SHIFT RELAY CIRCUIT 57 (BK) FOR AN OPEN 
    • Measure the resistance between gearmotor encoder assembly high-to-low shift relay C1173 pin 87A, circuit 57 (BK), harness side and ground.
      Fig 19: Checking Shift Relay Circuit 57 (BK) For Open
      G03909548Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to E30.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  30. E30 CHECK CIRCUITS 777 (YE) AND 778 (OG) FOR A SHORT TO GROUND 
    • Remove the gearmotor encoder assembly low-to-high shift relay.
    • Disconnect: Gearmotor Encoder C350b.
    • Measure the resistance between gearmotor encoder assembly C350b, circuit 777 (YE), harness side and ground; and between gearmotor encoder assembly C350b, circuit 778 (OG), harness side and ground.
      Fig 20: Checking Circuits 777 (YE) And 778 (OG) For Short To Ground
      G03909552Courtesy of FORD MOTOR CO.
    • Are the resistances less than 5 ohms? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to  E57.
  31. E31 REMOVE THE GEARMOTOR ENCODER ASSEMBLY FROM THE TRANSFER CASE 
    • Key in OFF position.
    • Remove the gearmotor encoder assembly. Refer to GEARMOTOR ENCODER ASSEMBLY  in this section.
    • Connect all connectors.
    • Enter the following diagnostic mode on the scan tool: Clear all DTCs.
    • Start the vehicle and allow to idle.
    • Key in OFF position.
    • Key in ON position.
    • Apply the parking brake.
    • Press the brake pedal.
    • Shift the transmission to NEUTRAL. For manual transmission, press and hold the clutch pedal.
    • Monitor 4WD control module PID VSS2, BPP and NTRL_SW. For manual transmission include, CLTCHSW.
    • Do the PID values reflect the vehicle condition? 
  32. E32 CHECK THE CONTACT PLATE ENCODER SWITCH 
    • Monitor mode select switch (MSS) PIDs 2WD, 4x4 and 4x4 LOW.
    • Monitor contact plate PIDs PLATE_A, PLATE_B, PLATE_C and PLATE_D.
    • Cycle the MSS to 2WD, 4x4 and 4x4 LOW two times.
    • Compare the contact plate PID values for each shift position selected by the MSS.
      CONTACT PLATE PID VALUES

      Plate PID MSS PID 2WD MSS PID 4WD MSS PID 4L0W
      PLATE_ A OPEN CLOSED CLOSED
      PLATE_B OPEN OPEN CLOSED
      PLATE_ C CLOSED CLOSED OPEN
      PLATE _D OPEN OPEN OPEN
    • Do the contact plate PID values agree with the MSS switch PIDs? 
    • Yes  : GO to E33.
    • No  : GO to  E36.
  33. E33 CHECK THE TRANSFER CASE 
    • Key in OFF position.
    • Release the parking brake.
    • Using a wrench, manually shift the transfer case sector shaft to the full clockwise (2WD) direction while turning the rear driveshaft.
    • Engage the parking brake.
    • Rotate the front driveshaft.
    • Does the front driveshaft turn? 
    • Yes  : GO to E34.
    • No  : REPAIR the transfer case. REFER to TRANSFER CASE . TEST the system for normal operation.
  34. E34 CHECK THE SECTOR SHAFT TURNING EFFORT 
    NOTE: The transfer case has four detented shift positions. The full clockwise position is 2WD, the next position is 4x4, then NEUTRAL and the full counterclockwise position is 4x4 LOW. Normal operation should not take more than 45 Nm (33 lb-ft) to manually shift the transfer case.
    • Release the parking brake.
    • Using a torque wrench, manually shift the transfer case sector shaft in a counterclockwise direction to the 4x4 detent position while rotating the rear driveshaft.
    • Did the torque required to shift exceed 45 Nm (33 lb-ft)? 
    • Yes  : REPAIR the transfer case as necessary. REFER to TRANSFER CASE . TEST the system for normal operation.
    • No  : GO to E35.
  35. E35 CHECK THE TRANSFER CASE SHIFT TO 4x4 AND 4x4 LOW 
    • Apply the parking brake.
    • Rotate the front driveshaft.
    • Does the front driveshaft rotate? 
    • Yes  : REPAIR the transfer case as necessary. REFER to TRANSFER CASE .
    • No  : INSTALL a new gearmotor encoder assembly. REFER to GEARMOTOR ENCODER ASSEMBLY  in this section. CLEAR the DTCs. REPEAT the self-test.
  36. E36 CHECK CONTACT PLATE GROUND CIRCUIT 3659 (BK/PK) 
    • Disconnect: Gearmotor Encoder Assembly C350a.
    • Measure the resistance between gearmotor encoder assembly C350a pin 4, circuit 3659 (BK/PK), harness side and ground.
      Fig 21: Checking Contact Plate Ground Circuit 3659 (BK/PK)
      G03909553Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E38.
    • No  : GO to E37.
  37. E37 CHECK CIRCUIT 3659 (BK/PK) FOR AN OPEN 
    • Disconnect: 4WD Control Module C281a.
    • Measure the resistance between gearmotor encoder assembly C350a pin 4, circuit 3659 (BK/PK), harness side and 4WD control module C281a pin 8, circuit 3659 (BK/PK), harness side.
      Fig 22: Checking Circuit 3659 (BK/PK) For Open
      G03909554Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E58.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  38. E38 CHECK CIRCUIT 976 (OG) FOR CONTACT PLATE VOLTAGE SUPPLY 
    • Key in ON position.
    • Measure the voltage between gearmotor encoder assembly C350a pin 2, circuit 976 (OG), harness side and ground. The voltage should be greater than 9 volts.
      Fig 23: Checking Circuit 976 (OG) For Contact Plate Voltage Supply
      G03909555Courtesy of FORD MOTOR CO.
    • Is the voltage reading as specified for the vehicle being tested? 
    • Yes  : GO to  E41.
    • No  : GO to E39.
  39. E39 CHECK CIRCUIT 976 (OG) FOR A SHORT TO GROUND 
    • Disconnect: 4WD Control Module C281a.
    • Measure the resistance between gearmotor encoder assembly C350a pin 2, circuit 976 (OG), harness side and ground.
      Fig 24: Checking Circuit 976 (OG) For Short To Ground
      G03909556Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to E40.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  40. E40 CHECK CIRCUIT 976 (OG) FOR AN OPEN 
    • Measure the resistance between gearmotor encoder assembly C350a pin 2, circuit 976 (OG), harness side and 4WD control module C281a pin 7, circuit 976 (OG), harness side.
      Fig 25: Checking Circuit 976 (OG) For Open
      G03909558Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E58.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  41. E41 CHECK CONTACT PLATE SWITCH A- CIRCUIT 771 (PK/YE) 
    • Connect: 4WD Control Module C281a.
    • Monitor the 4WD control module PID: PLATE_A.
    • Connect a jumper wire between gearmotor encoder assembly C350a pin 5, circuit 771 (PK/YE), harness side and ground.
      Fig 26: Checking Contact Plate Switch A- Circuit 771 (PK/YE)
      G03909559Courtesy of FORD MOTOR CO.
    • Does the PID: PLATE_A toggle between CLOSED and OPEN when ground is removed and applied? 
    • Yes  : GO to  E45.
    • No  : GO to E42.
  42. E42 CHECK CIRCUIT 771 (PK/YE) FOR A SHORT TO VOLTAGE 
    • Measure the voltage between gearmotor encoder assembly C350a pin 5, circuit 771 (PK/YE), harness side and ground.
      Fig 27: Checking Circuit 771 (PK/YE) For Short To Voltage
      G03909559Courtesy of FORD MOTOR CO.
    • Is voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E43.
  43. E43 CHECK CIRCUIT 771 (PK/YE) FOR A SHORT TO GROUND 
    • Measure the resistance between gearmotor encoder assembly C350a pin 5, circuit 771 (PK/YE), harness side and ground.
      Fig 28: Checking Circuit 771 (PK/YE) For Short To Ground
      G03909560Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to E44.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  44. E44 CHECK CIRCUIT 771 (PK/YE) FOR AN OPEN 
    • Disconnect: 4WD Control Module C281b.
    • Measure the resistance between gearmotor encoder assembly C350a pin 5, circuit 771 (PK/YE), harness side and 4WD control module C281b pin 9, circuit 771 (PK/YE), harness side.
      Fig 29: Checking Circuit 771 (PK/YE) For Open
      G03909562Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E58.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  45. E45 CHECK THE CONTACT PLATE SWITCH B - CIRCUIT 764 (BR/WH) 
    • Monitor the 4WD control module PID: PLATE_B.
    • Connect a jumper wire between gearmotor encoder assembly, C350a pin 3, circuit 764 (BR/WH), harness side and ground.
      Fig 30: Checking Contact Plate Switch B - Circuit 764 (BR/WH)
      G03909563Courtesy of FORD MOTOR CO.
    • Does the PID: PLATE_B toggle between CLOSED and OPEN when ground is removed and applied? 
    • Yes  : GO to  E49.
    • No  : GO to E46.
  46. E46 CHECK CIRCUIT 764 (BR/WH) FOR A SHORT TO VOLTAGE 
    • Measure the voltage between gearmotor encoder assembly C350a pin 3, circuit 764 (BR/WH), harness side and ground.
      Fig 31: Checking Circuit 764 (BR/WH) For Short To Voltage
      G03909563Courtesy of FORD MOTOR CO.
    • Is voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E47.
  47. E47 CHECK CIRCUIT 764 (BR/WH) FOR A SHORT TO GROUND 
    • Measure the resistance between gearmotor encoder assembly C350a pin 3, circuit 764 (BR/WH), harness side and ground.
      Fig 32: Checking Circuit 764 (BR/WH) For Short To Ground
      G03909565Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to E48.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  48. E48 CHECK CIRCUIT 764 (BR/WH) FOR AN OPEN 
    • Disconnect: 4WD Control Module C281b.
    • Measure the resistance between gearmotor encoder assembly C350a pin 3, circuit 764 (BR/WH), harness side and 4WD control module C281a pin 10, circuit 764 (BR/WH), harness side.
      Fig 33: Checking Circuit 764 (BR/WH) For Open
      G03909566Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E58.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  49. E49 CHECK CONTACT PLATE SWITCH C - CIRCUIT 770 (WH) 
    • Monitor the 4WD control module PID: PLATE_C.
    • Connect a jumper wire between gearmotor encoder assembly C350a pin 6, circuit 770 (WH), harness side and ground.
      Fig 34: Checking Contact Plate Switch C - Circuit 770 (WH)
      G03909567Courtesy of FORD MOTOR CO.
    • Does the PID: PLATE_C toggle between CLOSED and OPEN when ground is removed and applied? 
    • Yes  : GO to  E53.
    • No  : GO to E50.
  50. E50 CHECK CIRCUIT 770 (WH) FOR A SHORT TO VOLTAGE 
    • Measure the voltage between gearmotor encoder assembly C350a pin 6, circuit 770 (WH), harness side and ground.
      Fig 35: Checking Circuit 770 (WH) For Short To Voltage
      G03909567Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E51.
  51. E51 CHECK CIRCUIT 770 (WH) FOR A SHORT TO GROUND 
    • Measure the resistance between gearmotor encoder assembly C350a pin 6, circuit 770 (WH), harness side and ground.
      Fig 36: Checking Circuit 770 (WH) For Short To Ground
      G03909568Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to E52.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  52. E52 CHECK CIRCUIT 770 (WH) FOR AN OPEN 
    • Disconnect: 4WD Control Module C281a.
    • Measure the resistance between gearmotor encoder assembly C350a pin 6, circuit 770 (WH), harness side and 4WD control module C281a pin 11, circuit 770 (WH), harness side.
      Fig 37: Checking Circuit 770 (WH) For Open
      G03909569Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E58.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  53. E53 CHECK CONTACT PLATE SWITCH D - CIRCUIT 763 (OG/WH) 
    • Monitor the 4WD control module PID: PLATE_D.
    • Connect jumper wire between gearmotor encoder assembly C350a pin 1, circuit 763 (OG/WH), harness side and ground.
      Fig 38: Checking Contact Plate Switch D - Circuit 763 (OG/WH)
      G03909570Courtesy of FORD MOTOR CO.
    • Does the PID: PLATE_D toggle between CLOSED and OPEN when ground is removed and applied? 
    • Yes  : INSTALL a new gearmotor encoder assembly. REFER to GEARMOTOR ENCODER ASSEMBLY  in this section. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E54.
  54. E54 CHECK CIRCUIT 763 (OG/WH) FOR A SHORT TO VOLTAGE 
    • Measure the voltage between gearmotor encoder assembly C350a pin 1, circuit 763 (OG/WH), harness side and ground.
      Fig 39: Checking Circuit 763 (OG/WH) For Short To Voltage
      G03909571Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to E55.
  55. E55 CHECK CIRCUIT 763 (OG/WH) FOR A SHORT TO GROUND 
    • Measure the resistance between gearmotor encoder assembly C350a pin 1, circuit 763 (OG/WH), harness side and ground.
      Fig 40: Checking Circuit 763 (OG/WH) For Short To Ground
      G03909572Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to E56.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  56. E56 CHECK CIRCUIT 763 (OG/WH) FOR AN OPEN 
    • Disconnect: 4WD Control Module C281a.
    • Measure the resistance between gearmotor encoder assembly C350a pin 1, circuit 763 (OG/WH), harness side and 4WD control module C281a pin 12, circuit 763 (OG/WH), harness side.
      Fig 41: Checking Circuit 763 (OG/WH) For Open
      G03909573Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  E58.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  57. E57 CHECK CIRCUIT 777 (YE) AND 778 (OG) FOR A SHORT TO VOLTAGE 
    • Remove the gearmotor encoder high-to-low shift relay.
    • Remove the gearmotor encoder low-to-high shift relay.
    • Measure the voltage between gearmotor encoder assembly C350b, circuit 777 (YE), harness side and ground; and between gearmotor encoder assembly C350b, circuit 778 (OG), harness side and ground.
      Fig 42: Checking Circuit 777 (YE) And 778 (OG) For Short To Voltage
      G03909574Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
    • No  : CARRY OUT the ISO Relay Component Test on both shift relays. Refer to COMPONENT TESTING . CLEAR the DTCs. REPEAT the self-test.
  58. E58 CHECK FOR CORRECT MODULE OPERATION 
    • Check for:
      • corrosion
      • pushed-out pins
    • Connect any disconnected connectors making sure they are seated correctly.
    • Make sure all other system connectors are fully seated.
    • Operate the system and verify the concern is still present.
    • Is the concern still present? 
    • Yes  : INSTALL a new 4WD control module. REFER to FOUR-WHEEL DRIVE (4WD) CONTROL MODULE  in this section. CLEAR the DTCs. REPEAT the self-test.
    • No  : The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
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