AWD/TC/TCCU issue

[Stanley]

Hello everyone!

I’ve had my Ford Bronco for a month, and I need some help with an issue I’m facing.

I have a 2022 Ford Bronco Badlands + Sasquatch 2.7 L A/T. Mileage 6 462,

The errors detected by the FORScan scan are - C05D9, U0403.

Symptoms:

After starting the engine, I can hear the Transfer Case trying to switch from 2H to 4H or vice versa, or it seems to be performing some kind of position test; I'm not sure. There is a repetitive sound from under the car near the Transfer Case, as if it couldn't complete the task and keeps trying. After few unsuccessful attempts, the error "Check 4x4/Service Soon" appears.
Link to the recording (sound of TC trying to do something) -> https://photos.app.goo.gl/7wiPgggLvQFtPFtx8

Verified components:

1. Battery - carged and checked its ok.
2. Factory AWD module update - completed by local service.
3. I verified the harness and checked if the ground connection is secure.
4. Checked the connectors at the Transfer Case and ensured there are no loose connections.

Additionally what i discovered, the problem occurs when I get into the car, press the brake, and push the Start/Stop button; the engine runs for a moment, and the TC loops back and displays the error.

However,

If I first turn on the ignition and switch from GOAT mode to 2H to 4H/4A or use goat moads and then start the engine, the error does not appear, and I can drive with the system functioning properly.

Generally, with the ignition on but the engine not running, I can switch between drives (2H/4H/4A/4L, etc.) without issue. All GOAT modes are working.

Any help and guidance on what to do next would be greatly appreciated.

Thank you in advance for your help.

Best regards,
Adam

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[CitrusBronco]

Your description to me sounds like your bronco by default is not starting in 2h. Every bronco I have been in starts in 2h by default unless it was shut off in a mode like sport 4a mode and asks do you want to return when you start up. Is your bronco asking to return to x mode at startup?
If not have you made some program change that overrides the normal 2h startup?

 

[Stanley]

If I turn it off with 4H/4A, after restarting it asks me if I want to leave this mode, but even if I confirm, errors appear.

There were no changes in the program

 

[CitrusBronco]

So all start ups get the error, shut down and starting in normal 2 h or any 4x mode still throws the code.
Since I’ve never had one of theses modern transfer cases apart I don’t know what’s inside to make a suggestion. Sounds like could be software, solenoid, sensor acting up.
I think the dealer needs to get involved.
Hopefully one of the Ford techs we have on the board will have a easy resolution for you.

 

[Cobrafang]

I could be a bad position sensor in the diff. I think the techs should be able to troubleshoot. Take the service rep a little caesars large pizza or two...makes everything better

 

[adam1991]

https://www.bronco6g.com/forum/threads/updated-check-4x4-warning-alert-4a.32371/page-3#post-2327697

Brand new OBX with 4A, and had a bad transfer case.

 

[Stanley]

Hi,

The problem is solved, so I would like to share my experiences and close this thread.

Ultimately, it turned out that my transfer case had burned clutches, which resulted in errors when trying to control/set the 4A/4H mode.

I replaced the clutches myself and the entire work took me 4.5 hours.

The transfer case clutch pack with 4A mode is numbered MB3Z-7C108-A and can be purchased for +/- $150-220.

Burned clutches

New ones

I am sending you the links that I used as a source of knowledge on how to replace the clutch pack

 

[Ducati1098]

Hello everyone!

I’ve had my Ford Bronco for a month, and I need some help with an issue I’m facing.

I have a 2022 Ford Bronco Badlands + Sasquatch 2.7 L A/T. Mileage 6 462,

The errors detected by the FORScan scan are - C05D9, U0403.

Is there a reason you didn't just have it fix under warranty?

 

[Stanley]

I imported a car from the US to the EU. In my country they don't honor the warranty, and what's more they don't even want to service the car.....

 

[Ducati1098]

I imported a car from the US to the EU. In my country they don't honor the warranty, and what's more they don't even want to service the car.....

Ah okay. That makes sense

 

[Brian_B]

Nice work and great post!

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