4WD Module replaced twice by dealer, still have fault codes, looking for guidance

[2BRONCO1]

Hi all,
I have a 2021 BD Sasquatch, 2.7L, 4A transfer case, 57,000km. In May 2025, "Check 4wd" and "Check advance track" codes appeared, and it would not go into any 4wd modes, and no lights on the Goat dial. At that time my dealership replaced the 4wd module (part #MB3Z 7P238 D) under the drivetrain warranty, as the bumper to bumper warranty had expired. Same issued occurred in July 2025, it was intermittent, dealer checked and found nothing wrong (codes were not present at the time). Seems to occur when it is wet or damp outside, but it will return to normal if it is dry out. I replaced the battery September 2025, thinking issue was related to old battery. It's not a daily driver, so I leave the vehicle plugged into battery tender when I can.
Same issue returned this March, took it to dealer on April 1, they replaced the same module again, this time only 60% was covered by Ford warranty.
This morning same error codes returned, vehicle was not plugged in, and haven't been driven in 4 days. Vehicle was charging at 15+ volts while I was driving. I'm going to take it back to dealership, but looking for some input from the experts on the forum. Maybe Ducati1098? Could it be related to low voltage battery from sitting days in between drives? I'm doubting the new module is faulty, or any of the two previous modules for that matter as the issue keeps reoccurring. Any help or suggestions would be appreciated before I take it back to dealership!

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[Brian_B]

It's possible it's voltage related - but you've replaced the battery and you are seeing good voltage while running, indicating the alternator is working as well.

Given that the module has already been replaced - you really need to see codes. The ABS module can also flag a wrench/Check 4x4 fault, and possibly other modules as well. We've also seen where external components and wiring harnesses have gotten damaged and that has been the underlaying cause of issues. Wheel Speed Sensors (and their harnesses) are very common, I've seen at least one person who had an issue with their tone ring on the axle, and at least one issue where mud/grit got up in a wiring harness and damaged wiring insulation inside of sleeving.

 

[ThunderFlash]

The wet/dry thing certainly points to an electrical problem. I too have seen several posts where ABS wheel speed sensors were at the root of those codes you mentioned.

Maybe @Ducati1098 can give you some diagnostic tips to help out.

 

[flip]

VIN?

 

[2BRONCO1]

 

[2BRONCO1]

These two are April 2025

 

[2BRONCO1]

 

[2BRONCO1]

These codes are last week

 

[Ducati1098]

Hi all,
I have a 2021 BD Sasquatch, 2.7L, 4A transfer case, 57,000km. In May 2025, "Check 4wd" and "Check advance track" codes appeared, and it would not go into any 4wd modes, and no lights on the Goat dial. At that time my dealership replaced the 4wd module (part #MB3Z 7P238 D) under the drivetrain warranty, as the bumper to bumper warranty had expired. Same issued occurred in July 2025, it was intermittent, dealer checked and found nothing wrong (codes were not present at the time). Seems to occur when it is wet or damp outside, but it will return to normal if it is dry out. I replaced the battery September 2025, thinking issue was related to old battery. It's not a daily driver, so I leave the vehicle plugged into battery tender when I can.
Same issue returned this March, took it to dealer on April 1, they replaced the same module again, this time only 60% was covered by Ford warranty.
This morning same error codes returned, vehicle was not plugged in, and haven't been driven in 4 days. Vehicle was charging at 15+ volts while I was driving. I'm going to take it back to dealership, but looking for some input from the experts on the forum. Maybe Ducati1098? Could it be related to low voltage battery from sitting days in between drives? I'm doubting the new module is faulty, or any of the two previous modules for that matter as the issue keeps reoccurring. Any help or suggestions would be appreciated before I take it back to dealership!

Looks like potentially a voltage supply or ground issue to the AWD module. I would guess it doesn’t have anything to do with the battery, because I would expect other low voltage codes also.
Unfortunately I’m not going to be much help here. This is really something that needs to be diagnosed in person.

 

[Ape Factory]

If it sits quite a bit, I'd look for damage to your wiring harness due to rodents. I didn't look up any of the codes but I'm guessing some are comms errors.

 

[Motovita]

Hi all,
I have a 2021 BD Sasquatch, 2.7L, 4A transfer case, 57,000km. In May 2025, "Check 4wd" and "Check advance track" codes appeared, and it would not go into any 4wd modes, and no lights on the Goat dial. At that time my dealership replaced the 4wd module (part #MB3Z 7P238 D) under the drivetrain warranty, as the bumper to bumper warranty had expired. Same issued occurred in July 2025, it was intermittent, dealer checked and found nothing wrong (codes were not present at the time). Seems to occur when it is wet or damp outside, but it will return to normal if it is dry out. I replaced the battery September 2025, thinking issue was related to old battery. It's not a daily driver, so I leave the vehicle plugged into battery tender when I can.
Same issue returned this March, took it to dealer on April 1, they replaced the same module again, this time only 60% was covered by Ford warranty.
This morning same error codes returned, vehicle was not plugged in, and haven't been driven in 4 days. Vehicle was charging at 15+ volts while I was driving. I'm going to take it back to dealership, but looking for some input from the experts on the forum. Maybe Ducati1098? Could it be related to low voltage battery from sitting days in between drives? I'm doubting the new module is faulty, or any of the two previous modules for that matter as the issue keeps reoccurring. Any help or suggestions would be appreciated before I take it back to dealership!

Sorry I can't help but can you explain the reasoning behind the 60% warranty coverage?

 

[2BRONCO1]

First time it was replaced, May 2025, service advisor said it was covered under the drivetrain warranty, 100% covered. When I took it back in this April for the same issue, they said I had to pay for it all, the last time it should not have been covered under the drivetrain warranty. So the compromise was that they would pay 60% of the second replacement.

 

[Snacktime]

Sounds exactly like the module failing or a connection issue to the module. Symptoms match when I locked up my AWD module trying to program it.

 

[BadlandsA51]

Has it ever been in any deep water, up to the frame or more? If so, looking at any connectors that may have been submerged would be a good place to start. If there is any corrosion in the connectors moisture can sometimes cause shorts between terminals.

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