Four Wheel Drive (4WD) Systems 2-Speed Torque-On-Demand: Notes

Special Tool(s)

Courtesy of FORD MOTOR COMPANY	Flex Probe Kit 105-R025D or equivalent
Courtesy of FORD MOTOR COMPANY	Fluke 77-IV Digital Multimeter FLU77-4 or equivalent
Courtesy of FORD MOTOR COMPANY	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Principles of Operation

The Expedition is equipped with an automatic electronic-shift system that allows the operator to choose between 2WD and 3 different 4WD modes where torque is transmitted to the front driveline via an electromechanical clutch. The operator can switch between 2WD (2H) mode, 4X4 AUTO (4A) mode or 4X4 (4H) mode at any speed or at a stop. To engage or disengage 4X4 LOW (4L) mode, the vehicle speed must be less than 5 km/h (3 mph) and the transmission must be in NEUTRAL.

Wheel slip is sensed by monitoring the average front and rear wheel speeds. Based on steering wheel angle, accelerator pedal position and wheel slip, a PWM signal is transmitted to the transfer case as torque is required.

The TCCM provides the ABS with current clutch duty cycle and whether or not ABS may command the clutch duty cycle.

The brake subsystem sends the following information signals to the 4WD system over the HS-CAN :

Occurrences of brake events and failures. Refer to Anti-Lock Brake System (ABS) and Stability Control .
Steering wheel angle status. Refer to Anti-Lock Brake System (ABS) and Stability Control .
Wheel speeds. Refer to Anti-Lock Brake System (ABS) and Stability Control .

A concern with any of the above listed brake system signals HS-CAN affects the operation of the 4WD system.

The APP output signal is provided to the TCCM from the PCM. This signal is used by the TCCM to control the transfer case clutch.

The shift motor sense plate, an integral part of the shift motor assembly, informs the TCCM of the transfer case position.

The electric shift motor is mounted externally to the transfer case. It drives a rotary cam which moves the range fork within the transfer case between the HIGH range (2H, 4A and 4H) and LOW range (4L) positions. For 2 speed torque on demand transfer cases the shift motor only moves when the 4X4 system is commanded between 2H, N and 4L.

The TCCM sends a duty cycle command to the clutch coil which activates the clutch within the transfer case.

The TCCM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under cruising conditions, the TCCM activates the transfer case clutch a minimum duty cycle (percentage of time the clutch is turned on), which allows for the slight difference between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. The TCCM increases the duty cycle to prevent or control slip under any of the following conditions:

Slip is detected
Heavy acceleration (throttle position)
Straight-ahead steering wheel angle

Feature inputs:

MSS
Steering wheel angle (from the ABS module)
TR position (from the PCM)
Transmission output torque (from the PCM)
Wheel speed signal (transmitted from the ABS module)
APP (from the PCM)
Transfer case shift motor contact plate position inputs A, B, C, D

Feature outputs:

PWM signal to the transfer case clutch
4WD message center indicators
Transfer case shift motor outputs

Shifts between 4X4 AUTO (4A) and 4X4 (4H) modes can be made at any speed. Listed below are the inputs and outputs needed by the TCCM to execute a change between any of these modes.

Feature inputs:

Wheel speed signal
APP (from the PCM)
MSS

Feature outputs:

Transfer case shift motor outputs
PWM signal to the transfer case clutch
4WD message center indicators

When shifting into or out of 4X4 LOW (4L) mode, the TCCM requires that the vehicle speed is less than 5 km/h (3 mph) and the transmission is in NEUTRAL.

Feature inputs:

APP (from the PCM)
MSS
Transfer case shift motor encoder contact plate position inputs A, B, C, D
Wheel speed signal (transmitted from ABS module)

Feature outputs:

Transfer case shift motor outputs
4WD message center indicators
PWM signal to the transfer case clutch

Inspection and Verification

1.

Verify the customer concern.

2.

Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical	Electrical
Halfshafts IWE Shift motor Driveshaft and U-joints Vacuum leaks Fluid leaks Matching tire sizes Transfer case	BJB fuses: 20 (20A) 27 (20A) 29 (10A) SJB mini fuse 35 (10A) Wiring harness MSS Transfer case clutch Connector(s) IWE vacuum solenoid Circuitry

3.

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

NOTE: Make sure to use the latest scan tool software release.

4.
If the cause is not visually evident, connect the scan tool to the DLC.

NOTE: The VCM LED prove-out confirms power and ground from the DLC are provided to the VCM.

5.
If the scan tool does not communicate with the VCM :
- check the VCM connection to the vehicle.
- check the scan tool connection to the VCM.
- refer to Module Communications Network , No Power To The Scan Tool, to diagnose no power to the scan tool.

NOTE: Before carrying out the self-test, make sure:

6.
- ignition is in RUN.
- 4A mode is selected (or the last mode selected before starting the self-test).
If the scan tool does not communicate with the vehicle:
- verify the ignition is in the ON position.
- refer to Module Communications Network to diagnose no response from the PCM.

7.

Carry out the network test.
- If the scan tool responds with no communication for one or more modules, refer to Module Communications Network .
- If the network test passes, retrieve and record CMDTCs.

8.

Clear the DTCs and carry out the self-test diagnostics for the TCCM.

9.

If the DTCs retrieved are related to the concern, go to the TCCM DTC Chart . For all other DTCs, refer to Multifunction Electronic Modules .

10.

If no DTCs related to the concern are retrieved, GO to SYMPTOM CHART - 4WD or GO to SYMPTOM CHART - NVH .