Diagnosis and Testing: Four Wheel Drive (4WD) Systems - Electronic Shift

308-07A-1 Four Wheel Drive (4WD) Systems 308-07A-1
DIAGNOSIS AND TESTING

Four Wheel Drive (4WD) Systems — When the mode select switch (MSS) on the
Electronic Shift instrument panel is turned, the 4X4 control module
(PCM) activates the electromagnetic clutch and
Special Tool(s) powers the transfer case shift motor. When the shift
motor reaches the desired position, as determined by
Vehicle Communication Module
(VCM) and Integrated the contact plate position inputs to the 4X4 control
Diagnostic System (IDS) module (PCM), power to the shift motor will be
software with appropriate removed. When the transfer case front and rear
hardware, or equivalent scan output shafts are synchronized, the spring loaded
tool lockup collar mechanically engages the mainshaft
hub to the drive sprocket. Finally, the front axle
integrated wheel ends (IWEs) are engaged and the
73III Automotive Meter
105-R0057 or equivalent electromagnetic clutch is deactivated.
Feature Inputs
• MSS
• Wheel speeds (via high-speed controller area
network [HS-CAN] communication from ABS
module)
88 Digital Multi-meter or
equivalent • Contact plate position inputs A, B, C, D
105-R0053 (grounded when closed, open circuit when open)
• Transmission neutral
Feature Outputs
• Transfer case synchronization clutch
Flex Probe Kit • Transfer case shift motor relays
105-R025B
• IWE vacuum solenoid
• Instrument cluster (IC) indicators (via HS-CAN
communication to IC)
• 4WD mode (via HS-CAN communication to
PCM)
Principles of Operation Inspection and Verification
The electronic shift on the fly (ESOF) system is an 1. Verify the customer concern.
electronic shift system that allows the operator to
2. Visually inspect for obvious signs of
choose between 2 different four wheel drive (4WD)
mechanical or electrical damage.
modes as well as two wheel drive (2WD). The
operator can switch between 2H and 4H mode at
speeds up to 88 km/h (55 mph). To engage or
disengage 4L range, the vehicle speed must be less
than 3 km/h (2 mph) and the transmission must be
in NEUTRAL (or the clutch pedal pressed in
manual transmission vehicles).
Copyright  2007, Ford Motor Company

Last updated: 9/26/2007 2008 F-150, Mark LT, 9/2007
DIAGNOSIS AND TESTING (Continued)
Visual Inspection Chart • check the scan tool connection to the VCM.
Mechanical Electrical • refer to Section 418-00, No Power To The
• Halfshafts • Central junction box Scan Tool, to diagnose no communication
• Integrated wheel ends (CJB) mini fuses: with the scan tool.
(IWEs) — 11 (10A)
• Shift motor — 28 (5A) 6. If the scan tool does not communicate with the
• Driveshaft and U-joints — 29 (15A) vehicle:
• Vacuum leaks — 30 (15A) • verify the ignition key is in the ON position.
• Fluid leaks — 111 (30A)
• Matching tire sizes • Wiring harness • Verify the scan tool operation with a known
• Transfer case • Mode select switch good vehicle.
(MSS)
• Synchronization clutch • refer to Section 418-00 to diagnose no
• Connector(s) response from the PCM.
• IWE vacuum solenoid 7. Carry out the network test.
• Circuitry
• If the scan tool responds with no
communication for one or more modules,
3. If an obvious cause for an observed or reported refer to Section 418-00.
concern is found, correct the cause (if possible)
• If the network test passes, retrieve and
before proceeding to the next step.
record continuous memory DTCs.
4. NOTE: Make sure to use the latest scan tool
8. Clear the continuous DTCs and carry out the
software release.
self-test diagnostics for the 4X4 control module
If the cause is not visually evident, connect the (PCM) and the instrument cluster (IC).
scan tool to the data link connector (DLC).
9. If the DTCs retrieved are related to the concern,
5. NOTE: The vehicle communication module go to the 4X4 Control Module (PCM) DTC
(VCM) LED prove out confirms power and Chart. For all other DTCs, refer to Section
ground from the DLC are provided to the 419-10.
VCM.
10. If no DTCs related to the concern are retrieved,
If the scan tool does not communicate with the GO to Symptom Chart.
VCM:
• check the VCM connection to the vehicle.
4X4 Control Module (PCM) DTC Chart
DTC Description Source Action

B1317 Battery Voltage High 4X4 Control CHECK the battery and charging system
Module for faults. REFER to Section 414-00.
(PCM) CLEAR the DTC. REPEAT the self-test.
B1318 Battery Voltage Low 4X4 Control CHECK the battery and charging system
Module for faults. REFER to Section 414-00.
(PCM) CLEAR the DTC. REPEAT the self-test.
B1342 ECU is Faulted 4X4 Control CLEAR the DTC. REPEAT the self-test.
Module If DTC B1342 is retrieved, INSTALL a
(PCM) 4X4 control module (PCM). REFER to
Section 303-14. REPEAT the self-test.
C1728 Transfer Case Unable to Transition 4X4 Control GO to Pinpoint Test J.
Between 2WD HIGH and 4WD HIGH Module
(PCM)
C1729 Transfer Case Unable to Transition 4X4 Control GO to Pinpoint Test K.
Between 4WD HIGH and 4WD LOW Module
(PCM)
2008 F-150, Mark LT, 9/2007

C1979 IWE Solenoid Circuit Failure 4X4 Control GO to Pinpoint Test I.
Module
(PCM)
C1980 IWE Solenoid Short to Battery 4X4 Control GO to Pinpoint Test I.
Module
(PCM)
P1812 4-Wheel Drive Mode Select Circuit 4X4 Control GO to Pinpoint Test J.
Failure Module
(PCM)
P1815 4-Wheel Drive Mode Select Short Circuit 4X4 Control GO to Pinpoint Test J.
to Ground Module
(PCM)
P1820 Transfer Case Clockwise Shift Relay 4X4 Control GO to Pinpoint Test J.
Coil Circuit Failure Module
(PCM)
P1822 Transfer Case Clockwise Shift Relay 4X4 Control GO to Pinpoint Test J.
Coil Short Circuit To Battery Module
(PCM)
P1824 4-Wheel Drive Clutch Relay Circuit 4X4 Control GO to Pinpoint Test L.
Failure Module
(PCM)
P1826 4-Wheel Drive Low Clutch Relay Circuit 4X4 Control GO to Pinpoint Test L.
to Battery Module
(PCM)
P1827 4-Wheel Drive Low Clutch Relay Circuit 4X4 Control GO to Pinpoint Test L.
to Ground Module
(PCM)
P1828 Transfer Case Counter Clockwise Shift 4X4 Control GO to Pinpoint Test J.
Relay Coil Circuit Failure Module
(PCM)
P1830 Transfer Case Counter Clockwise Shift 4X4 Control GO to Pinpoint Test J.
Relay Coil Short Circuit To Battery Module
(PCM)
P1849 Transmission Transfer Case Contact Plate 4X4 Control GO to Pinpoint Test J.
A Short Circuit to Ground Module
(PCM)
B Short Circuit to Ground Module
(PCM)
C Short Circuit to Ground Module
(PCM)
D Short Circuit to Ground Module
(PCM)
General Circuit Failure Module
(PCM)
Ground Return Open Circuit Module
(PCM)
2008 F-150, Mark LT, 9/2007

U1900 CAN Communication BUS Fault — 4X4 Control NOTE:
Received Error Module Do not install a new 4X4 control module
(PCM) as part of repair for 4X4 control module
DTC U1900 fault. The 4X4 control
module is not the source of the fault
when DTC U1900 is present.
CARRY OUT the network test to
identify the module the 4X4 control
module lost communication with. REFER
to Section 418-00 to diagnose the module
communication.
U2023 Fault Received From External Node 4X4 Control Invalid/faulted HS-CAN wheel speed
Module message data. REFER to Section 206-09
(PCM) to diagnose wheel speed sensor fault.
U2051 One Or More Calibration Files 4X4 Control This DTC is cleared when
Missing/Corrupt Module reprogramming. CARRY OUT
(PCM) programmable module installation (PMI).
REFER toSection 418-01.
Symptom Chart
Symptom Chart
Condition Possible Sources Action
• No communication with the • Scan tool • REFER to Section 418-00.
4X4 control module (PCM) • Data link connector (DLC)
• 4X4 control module (PCM)
• Circuitry
• The instrument cluster (IC) • IC • GO to Pinpoint Test P.
4X4 LOW and 4X4 HI • Circuitry
indicators do not operate • 4X4 control module (PCM)
correctly/do not operate • Ignition switch
• The vehicle does not shift • Mode select switch (MSS) • GO to Pinpoint Test J.
between two wheel drive • Transfer case
(2WD) and four wheel drive • Transfer case clutch
(4WD) modes correctly • Integrated wheel ends (IWEs)
• Circuitry
• Ignition switch
• The vehicle does not shift • Transfer case • GO to Pinpoint Test K.
between 4H and 4L modes • MSS
correctly • 4X4 control module (PCM)
• Transmission drag torque
• Ignition switch
• 4WD does not engage at • Transfer case clutch coil • GO to Pinpoint Test L.
speed correctly • 4X4 control module (PCM)
• IWEs
• Ignition switch
• The front axle does not • MSS • GO to Pinpoint Test I.
engage/disengage • IWEs
correctly/makes noise in 2H • IWE solenoid
under heavy throttle • Vacuum leaks
• Front halfshaft
• Ignition switch
2008 F-150, Mark LT, 9/2007

Symptom Chart (Continued)
Condition Possible Sources Action
• The transfer case jumps out • Transfer case • GO to Pinpoint Test M.
of gear • IWE vent
• MSS
• Straightline driveline wind-up • Tire inflation pressure • GO to Pinpoint Test N.
• Tire and wheel size
• Tire wear
• Axle ratio
• Grinding noise during 4WD • Front halfshaft speeds not • INSTALL the S-spring in the
engagement, especially at turning at the same speed front differential. REFER to
high speeds Section 205-03 for S-spring
installation.
• Flashing 4X4 LOW and 4X4 • Loss of high-speed controller • CHECK the IC for faults.
HI indicators 3 times every 2 area network (HS-CAN) REFER to Section 413-01.
minutes communication between 4X4
control module (PCM) and IC
• No communication with the • CHECK 4X4 control module
4X4 control module (PCM) (PCM) communication.
• Ignition switch REFER to Section 418-00.
• The transfer case makes noise • Tire inflation pressure • MAKE SURE that all tires
• Tire and wheel size and wheels are the same size
and that the inflation
pressures are correct.
• Tire tread wear • CHECK tire tread wear to see
if there is more than 0.15 mm
(0.06 in) difference in tread
wear between front and rear.
INTERCHANGE one front
wheel and one rear wheel.
ROAD TEST again.
• Internal components • OPERATE the vehicle in all
transmission gears. If there is
noise in the transmission in
NEUTRAL, or in some gears
and not in others, REMOVE
and REPAIR the
transmission. REFER to
Section 307-01. If there is
noise in all gears,
DISASSEMBLE the transfer
case. REFER to Section
308-07B. CHECK the
planetary gears, the bearings,
the upper and lower drive
sprockets and drive chain for
damage. INSTALL new parts
as necessary.
• Fluid level • FILL with automatic
transmission fluid. REFER to
Section 308-07B.
• Unable to duplicate customer • 4WD system and/or related • CARRY OUT the Electronic
concern components Shift on the Fly (ESOF)
Functional Test. GO to
Pinpoint Test O.
2008 F-150, Mark LT, 9/2007

Pinpoint Tests • DTC C1980 IWE Solenoid Short to Battery—
IWE solenoid short to battery sensed by the 4X4
Pinpoint Test I: The Front Axle Does Not control module (PCM) C175B pin 16.
Engage/Disengage Correctly/Makes Noise in
2H Under Heavy Throttle This pinpoint test is intended to diagnose
the following:
Refer to Wiring Diagrams Cell 34, Four-Wheel
Drive System for schematic and connector • MSS
information. • IWE
Normal Operation • IWE solenoid
In two wheel drive (2WD), the 4X4 control module • Transfer case
(PCM) supplies a ground path to the integrated
wheel end (IWE) solenoid to apply vacuum to the • Vacuum leaks
IWEs (disengaging the front hubs from the front • Front axle assembly
axle). In four wheel drive (4WD), the 4X4 control • 4X4 control module (PCM)
module (PCM) does not supply the ground path to
• Wiring, terminals or connectors
the IWE solenoid, vacuum is not applied to the
IWEs and an internal spring keeps the hubs • Fuses
engaged. Systematically check the necessary inputs
and outputs at the 4X4 control module (PCM),
internal components of the transfer case, mode
select switch (MSS), IWE components and drive
axles.
• DTC C1979 IWE Solenoid Circuit Failure —
IWE solenoid open circuit or short to ground
sensed by the 4X4 control module (PCM) C175B
pin 16.
PINPOINT TEST I: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY/MAKES NOISE IN
2H UNDER HEAVY THROTTLE
Test Step Result / Action to Take
I1 CHECK FOR DTCs
• Connect the scan tool. Yes
• Key in ON position. If DTC C1979 is retrieved, GO to I13.
• Carry out the 4X4 control module on-demand self test. If DTC C1980 is retrieved, GO to I15.
• Are DTCs C1979 or C1980 present?
No
GO to I2.
I2 CHECK FOR GRINDING NOISES AT HIGH SPEEDS
• Turn the MSS from 2H to 4H at rest. Drive the vehicle. Yes
• Turn the MSS from 2H to 4H while driving the vehicle at low If the concern is excessive front axle noise
speed. during 4WD engagement (especially at
• Turn the MSS from 2H to 4H while driving the vehicle at high high speeds), INSTALL the S-spring in the
speed. front differential. REFER to Section
• Is the axle system fully functional at rest, but there is a 205-03.
grinding noise during engagement, especially at high No
speed? GO to I3.
I3 CHECK THE TRANSFER CASE SHIFT TO 2H
• Key in ON position.
• Enter the following diagnostic mode on the scan tool:
DataLogger — 4X4 Control Module.
• Using the active command contact plate power (PLATE PWR)
to energize the transfer case motor contact plate position return
circuit.
• Monitor the 4X4 control module (PCM) transfer case contact
plate switch A (PLATE A), B (PLATE B), C (PLATE C) and
D (PLATE D) PIDs for the contact plate position with the MSS
in the 2H position.
(Continued)
2008 F-150, Mark LT, 9/2007

2H UNDER HEAVY THROTTLE (Continued)
I3 CHECK THE TRANSFER CASE SHIFT TO 2H (Continued)
MSS Contact Plate Position

Position PLATE A PLATE B PLATE C PLATE D
2H Mode CLOSED OPEN CLOSED CLOSED
4H Mode OPEN CLOSED CLOSED OPEN
4L Mode OPEN CLOSED OPEN CLOSED Yes
End the active command. GO to I4.
• Did the 4X4 control module (PCM) PIDs and instrument No
cluster (IC) message center indicate that vehicle shifted into End the active command. GO to Pinpoint
2H? Test J.
I4 CHECK THE IWE DISENGAGEMENT
• With the vehicle in NEUTRAL, position it on a hoist. Refer to
Section 100-02.
• NOTE: The engine must be idling during the following steps to
supply vacuum to the IWE solenoid.
Start the engine and allow to idle.
• Switch the MSS to 2H.
• Rotate the LH front tire one revolution forward and one
revolution backward while observing the LH front halfshaft. Yes
• Rotate the RH front tire one revolution forward and one GO to I10.
revolution backward while observing the RH front halfshaft. No
• Did either front halfshaft rotate? GO to I5.
I5 CHECK THE TRANSFER CASE SHIFT INTO 4H
• Re-enter DataLogger and deselect then reselect the contact
plate power (PLATE PWR) active command.
• Using the active command PLATE PWR energize the transfer
case motor contact plate position return circuit.
plate switch A (PLATE A), B (PLATE B), C (PLATE C) and
D (PLATE D) PIDs for the contact plate position with the MSS
in the 4H position.

4H Mode OPEN CLOSED CLOSED OPEN Yes
4L Mode OPEN CLOSED OPEN CLOSED End the active command. GO to I6.
No
• Did the 4X4 control module (PCM) PIDs and IC message End the active command. GO to Pinpoint
center indicate that the vehicle shifted into 4H? Test J.
I6 CHECK THE IWE ENGAGEMENT
Section 100-02.
Start the engine and allow to idle. Yes
• Switch the MSS to 4H. CHECK that all driveline fasteners are
• Rotate the LH front tire one revolution forward and one present and tightened to specification.
revolution backward while observing the LH front halfshaft. REFER to Section 205-00 for further
• Rotate the RH front tire one revolution forward and one diagnosis of the front axle.
revolution backward while observing the RH front halfshaft. No
• Did both front halfshafts rotate? GO to I7.
(Continued)
2008 F-150, Mark LT, 9/2007

I7 CHECK THE IWE SOLENOID OUTPUT IN 4H
Disconnect the output vacuum line at the IWE solenoid.
• Switch the MSS to 4H. Yes
• With the engine still running, measure the vacuum at the output Key in OFF position. GO to I25.
port of the IWE solenoid. No
• Is the vacuum less than 25 mm (1 in) Hg? GO to I8.
I8 CHECK THE IWE SOLENOID OUTPUT IN 4H USING THE
INTEGRATED WHEEL ENDS SOLENOID (IWE SOL) ACTIVE
COMMAND
With the engine still running, use the scan tool to command Yes
IWE SOL to OFF to engage the IWEs (solenoid OFF). End active command. GO to I19.
• Measure the vacuum at the output port of the IWE solenoid. No
• Is the vacuum less than 25 mm (1 in) Hg? GO to I9.
I9 CHECK THE IWE SOLENOID
• Disconnect: IWE Solenoid C1290.
• With the engine still running, use the scan tool to command Yes
IWE SOL to OFF to engage the IWEs (solenoid OFF). End active command. GO to I17.
• With the engine still running, measure the vacuum at the output No
port of the IWE solenoid. End active command. INSTALL a new
• Is the vacuum less than 25 mm (1 in) Hg? IWE solenoid. REPEAT the self-test.
I10 CHECK THE IWE SOLENOID OUTPUT VACUUM IN 2H
Disconnect the output vacuum line at the IWE solenoid.
• With the engine still running, measure the vacuum at the output GO to I20.
port of the IWE solenoid. No
• Is the vacuum greater than 254 mm (10 in) Hg? GO to I11.
I11 CHECK THE IWE SOLENOID INPUT VACUUM
• With the engine still running, measure the vacuum at the input Yes
port of the IWE solenoid. GO to I12.
• Is the vacuum greater than 254 mm (10 in) Hg? No
REPAIR the vacuum leak. CLEAR the
DTCs. REPEAT the self-test.
I12 CHECK THE IWE SOLENOID OUTPUT IN 2H MODE USING THE
INTEGRATED WHEEL ENDS SOLENOID (IWE SOL) ACTIVE
COMMAND
With the engine still running, use the scan tool to command Yes
IWE SOL to ON to engage the IWEs (solenoid ON). End active command. GO to I19.
• Measure the vacuum at the output port of the IWE solenoid. No
• Is the vacuum greater than 254 mm (10 in) Hg? End active command. GO to I13.
I13 CHECK CIRCUIT 883 (PK/LB) FOR VOLTAGE
• Key in OFF position.
(Continued)
2008 F-150, Mark LT, 9/2007

I13 CHECK CIRCUIT 883 (PK/LB) FOR VOLTAGE (Continued)
• Measure the voltage between IWE solenoid C1291-1, circuit 883
(PK/LB) and ground.
Yes
GO to I14.
No
CHECK central junction box (CJB) fuse 11
(10A). VERIFY that the fuse blows when
the A/C system compressor cycles. If this
occurs, REFER to Section 412-00.
REPAIR the circuit as necessary. CLEAR
• Is the voltage greater than 9 volts? the DTCs. REPEAT the self-test.
I14 CHECK THE IWE SOLENOID OPERATION
• Connect: IWE Solenoid C1291.
supply the vacuum required for the IWEs to engage and
disengage.
Start the engine. Yes
• Connect a fused jumper wire between the IWE solenoid DISCONNECT the fused jumper. GO to
C1291-2, circuit 605 (RD), component side and ground. I15.
• Measure the vacuum at the IWE solenoid output vacuum port. No
• Is the IWE solenoid output port vacuum greater than 254 INSTALL a new IWE solenoid. CLEAR the
mm (10 in) Hg? DTCs. REPEAT the self-test.
I15 CHECK CIRCUIT 605 (RD) FOR A SHORT TO VOLTAGE
• Disconnect: 4X4 Control Module (PCM) C175B.
• Measure the voltage between IWE solenoid C1291-2, circuit 605
(RD), harness side and ground.
Yes
REPAIR the circuit. CLEAR the DTCs.
REPEAT the self-test.
No
• Is any voltage present? GO to I16.
I16 CHECK CIRCUIT 605 (RD) FOR AN OPEN
(Continued)
2008 F-150, Mark LT, 9/2007

I16 CHECK CIRCUIT 605 (RD) FOR AN OPEN (Continued)
• Measure the resistance between IWE solenoid C1291-2, circuit
605 (RD), harness side and 4X4 control module (PCM)
C175B-16, circuit 605 (RD), harness side.
Yes
GO to I17.
No
• Is the resistance less than 5 ohms? REPEAT the self-test.
I17 CHECK CIRCUIT 605 (RD) FOR A SHORT TO GROUND
• Measure the resistance between IWE solenoid C1291-2, circuit
605 (RD), harness side and ground.
Yes
GO to I18.
No
• Is the resistance greater than 10,000 ohms? REPEAT the self-test.
I18 CHECK THE IWE SOLENOID RESISTANCE
• Measure the resistance between IWE solenoid C1291-1 and
C1291-2, component side.
Yes
GO to I19.
No
INSTALL a new IWE solenoid. CLEAR the
• Is the resistance between 73 and 78 ohms? DTCs. REPEAT the self-test.
(Continued)
2008 F-150, Mark LT, 9/2007

I19 CHECK THE 4X4 CONTROL MODULE (PCM)
• Key in OFF position. Yes
• Disconnect all 4X4 control module (PCM) connectors. INSTALL a new 4X4 control module
• Check for: (PCM). REFER to Section 303-14.
— corrosion. REPEAT the self-test.
— pushed-out pins. No
• Connect all 4X4 control module (PCM) connectors and make The system is operating correctly at this
sure they are seated correctly. time. Concern may have been caused by
• Operate the system and verify the concern is still present. a loose or corroded connector. CLEAR the
• Is the concern still present? DTCs. REPEAT the self-test.
I20 CHECK THE IWE VACUUM SYSTEM
• Disconnect both vacuum lines from the IWE solenoid.
• Using a vacuum pump, apply 508 mm (20 in) Hg of vacuum to Yes
the IWE system through the apply vacuum circuit. GO to I21.
• Observe the vacuum reading. No
• Did the vacuum drop more than 25 mm (1 in) Hg per CONNECT the vacuum lines to the IWE
minute? solenoid. GO to I24.
I21 CHECK THE RH IWE LEAK RATE
Section 100-02. Yes
• Disconnect the vacuum line from the larger port on the RH IWE. INSTALL a new RH IWE. REFER to
• Apply 508 mm (20 in) Hg of vacuum to the RH IWE port and Section 205-04, halfshaft removal and
observe vacuum reading. installation. GO to I20.
• Did the vacuum drop more than 25 mm (1 in) Hg per No
minute? GO to I22.
I22 CHECK THE LH IWE LEAK RATE
• Disconnect the vacuum line from the larger port at the LH IWE. Yes
• Apply 205 mm (20 in) Hg of vacuum to the LH IWE port and INSTALL a new LH IWE. REFER to
observe vacuum reading. Section 205-04, halfshaft removal and
• Did the vacuum drop more than 25 mm (1 in) Hg per installation. GO to I20.
minute? No
GO to I23.
I23 CHECK THE IWE VACUUM SUPPLY TUBE
• Plug both LH and RH IWE vacuum lines. Apply 508 mm (20 in) Yes
Hg of vacuum to the IWE apply vacuum circuit and observe the INSTALL new vacuum lines as necessary.
vacuum reading. GO to I20.
minute? GO to I24.
I24 CHECK THE IWE VACUUM SUPPLY AT EACH IWE IN 2H
• Connect a hand-held vacuum gauge to the LH IWE vacuum
supply tube.
supply the vacuum required for the IWEs to engage and
disengage. Yes
Start the engine. GO to I27.
• Switch the MSS to 2H while observing the vacuum gauge. No
• Repeat these steps for the RH IWE. INSTALL new vacuum lines as necessary.
• Are the vacuum readings greater than 254 mm (10 in) Hg? GO to I20.
I25 CHECK THE LH IWE VACUUM LINE FOR AN OBSTRUCTION
Section 100-02. Yes
• Disconnect the vacuum line at the LH IWE. INSTALL a new vacuum line. CLEAR the
• Connect a hand vacuum pump to the LH IWE vacuum line and DTCs. REPEAT the self-test.
attempt to draw a vacuum on the line. No
• Did the vacuum pump draw a vacuum on the LH IWE CONNECT the vacuum line to the LH
vacuum line? IWE. GO to I26.
(Continued)
2008 F-150, Mark LT, 9/2007

I26 CHECK THE RH IWE VACUUM LINE FOR AN OBSTRUCTION
• Disconnect the larger vacuum line at the RH IWE. Yes
• Connect a vacuum pump to the RH IWE vacuum line and INSTALL a new vacuum line. CLEAR the
attempt to draw a vacuum on the line. DTCs. REPEAT the self-test.
• Did the vacuum pump draw a vacuum on the RH IWE No
vacuum line? CONNECT the vacuum line to the RH
IWE. GO to I27.
I27 CHECK THE LH IWE OPERATION
Section 100-02. Yes
• Connect a vacuum pump to the larger IWE vacuum port. GO to I28.
• Observe the LH halfshaft while rotating the LH front tire. Apply No
and release vacuum to manually engage and disengage the LH INSTALL a new LH IWE. REFER to
IWE. Section 205-04, halfshaft removal and
• Did the LH IWE disengage between 152 and 203 mm (6 to 8 installation. CLEAR the DTCs. REPEAT
in) Hg? the self-test.
I28 CHECK THE RH IWE OPERATION
• Connect a vacuum pump to the larger RH IWE vacuum port. Yes
• Observe the RH halfshaft while rotating the RH front tire. Apply CLEAR the DTCs. REPEAT the self-test.
and release vacuum to manually engage and disengage the LH GO to Pinpoint Test O.
IWE. No
• Did the RH IWE disengage between 152 and 203 mm (6 to 8 INSTALL a new RH IWE. REFER to
in) Hg? Section 205-04, halfshaft removal and
installation. CLEAR the DTCs. REPEAT
the self-test.
Pinpoint Test J: The Vehicle Does Not Shift Normal Operation

Between Two Wheel Drive (2WD) and Four The mode select switch (MSS) communicates the
Wheel Drive (4WD) Modes Correctly operator’s choice to the 4X4 control module (PCM).
Refer to Wiring Diagrams Cell 34, Four-Wheel The 4X4 control module (PCM) then controls the
Drive System for schematic and connector transfer case clutch, transfer case motor and
information. integrated wheel ends (IWEs) as necessary. If the
vehicle is not responding to the operator’s
intentions, systematically check the necessary inputs
and outputs of the 4X4 control module (PCM),
components of the transfer case, IWE components
and halfshafts. Check all circuits for opens and
shorts to power or ground.
DTC Description Fault Trigger Condition

C1728 — Transfer Case Unable to Transition Between Failure to reach designated motor position within allotted
2WD HIGH and 4WD HIGH time after multiple retries.
P1812 — 4-Wheel Drive Mode Select Circuit Failure Open or short circuit to battery sensed by the 4X4 control
module (PCM) C175B pin 32.
P1815 — 4-Wheel Drive Mode Select Short Circuit to Short to ground sensed by the 4X4 control module (PCM)
Ground C175B pin 32.
P1820 — Transfer Case Clockwise Shift Relay Coil Short to ground or open circuit sensed by the 4X4 control
Circuit Failure module (PCM) C175B pin 14.
P1822 — Transfer Case Clockwise Shift Relay Coil Short Short circuit to battery sensed by the 4X4 control module
Circuit To Battery (PCM) C175B pin 14.
P1828 — Transfer Case Counter Clockwise Shift Relay Short to ground or open circuit sensed by the 4X4 control
Coil Circuit Failure module (PCM) C175B pin 15.
2008 F-150, Mark LT, 9/2007

P1830 — Transfer Case Counter Clockwise Shift Relay Short circuit to battery sensed by the 4X4 control module
Coil Short Circuit To Battery (PCM) C175B pin 15.
P1849 — Transmission Transfer Case Contact Plate A Short circuit to ground sensed by the 4X4 control module
Short Circuit to Ground (PCM) C175T pin 6.
P1853 — Transmission Transfer Case Contact Plate B Short circuit to ground sensed by the 4X4 control module
P1857 — Transmission Transfer Case Contact Plate C Short circuit to ground sensed by the 4X4 control module
P1861 — Transmission Transfer Case Contact Plate D Short circuit to ground sensed by the 4X4 control module
P1867 — Transmission Transfer Case Contact Plate General motor encoder fault, invalid motor position
General Circuit Failure detected when new 4WD mode is selected or during a
motor movement.
P1891 — Transmission Transfer Case Contact Plate Open circuit sensed by the 4X4 control module (PCM)
Ground Return Open Circuit C175T pin 46.
This pinpoint test is intended to diagnose • 4X4 control module (PCM)

the following:
• Front axle assembly
• Transfer case
• IWE
• MSS
• IWE solenoid
PINPOINT TEST J: THE VEHICLE DOES NOT SHIFT BETWEEN TWO WHEEL DRIVE (2WD) AND FOUR
WHEEL DRIVE (4WD) MODES CORRECTLY
J1 CHECK FOR DTCs
• Carry out the 4X4 control module on-demand self test. If DTC P1812, GO to J4. If DTC P1815,
• Are DTCs retrieved? GO to J7. If DTC P1867 or P1891, GO to
J16. If DTC P1849, P1853, P1857 or
P1861, GO to J18. If DTC P1820 or
P1828, GO to J21. If DTC P1822, P1830,
or C1728, GO to J29.
No
GO to J2.
J2 CHECK THE IGNITION SWITCH RUN/START POSITION
(IGN R/S) AND START (POSITION 3) (IGN S) PIDs
• Enter the following diagnostic mode on the scan tool: Yes
DataLogger — 4X4 Control Module. GO to J3.
• Monitor the IGN R/S and IGN S PIDs. No
• Do the ignition switch PIDs match the ignition switch If the IGN R/S PID did not match,
positions? CHECK central junction box (CJB) fuse 28
(5A). If the fuse is OK, REPAIR circuit
1856 (GY/OG). After the fault is repaired,
CLEAR the DTCs. REPEAT the self test.
If the IGN S PID did not match, REFER
to Section 211-05 to diagnose the ignition
switch. After the fault is repaired, CLEAR
the DTCs. REPEAT the self test.
J3 CHECK THE MSS POSITION MONITORING THE 4WD SWITCH
STATUS (4WDINP SW) PID
• Monitor the 4WDINP SW PID while cycling through each MSS Yes
position. GO to J8.
• Does the 4WDINP SW PID agree with each switch No
position? GO to J4.
(Continued)
2008 F-150, Mark LT, 9/2007

WHEEL DRIVE (4WD) MODES CORRECTLY (Continued)
J4 CHECK THE MSS
• Disconnect: MSS C284.
• Measure the resistance between MSS C284-2 and C284-3
component side, while rotating the switch through all positions.
Refer to the following chart.
MSS Position Resistance

4L 130 ohms
4H 270 ohms
2H 620 ohms
Yes
GO to J5.
No
INSTALL a new MSS. REFER to Mode
Select Switch (MSS) in this section.
• Are the resistance values within specification? CLEAR the DTCs. REPEAT the self-test.
J5 CHECK CIRCUITS 682 (DB) AND 780 (DB) FOR AN OPEN
• Measure the resistance between MSS C284-2, harness side and
4X4 control module (PCM) C175B-31, harness side, circuit 682
(DB); and between MSS C284-3, harness side and 4X4 control
module (PCM) C175B-32 harness side, circuit 780 (DB).
Yes
GO to J6.
No
REPAIR the affected circuit(s). CLEAR the
• Is the resistance less than 5 ohms? DTCs. REPEAT the self-test.
J6 CHECK CIRCUITS 682 (DB) AND 780 (DB) FOR SHORT TO
VOLTAGE
(Continued)
2008 F-150, Mark LT, 9/2007

VOLTAGE (Continued)
• Measure the voltage between MSS C284-2, circuit 682 (DB),
harness side and ground; and between MSS C284-3, circuit 780
(DB) harness side and ground.
Yes
No
• Is any voltage present? GO to J7.
GROUND
• Measure the resistance between MSS C284-2, circuit 682 (DB),
harness side and ground; and between MSS C284-3 circuit 780
(DB), harness side and ground.
Yes
GO to J30.
No
• Is the resistance greater than 10,000 ohms? DTCs. REPEAT the self-test.
J8 CHECK FOR 4H WIND-UP
• Drive the vehicle on a dry, hard surface in turns. GO to J11.
• Is wind-up present in turns? No
GO to J9.
J9 CHECK FOR TRANSFER CASE ENGAGEMENT
Section 100-02. Yes
• Rotate the rear driveshaft. GO to J10.
• Observe the front driveshaft. No
• Did the front driveshaft rotate? GO to J14.
(Continued)
2008 F-150, Mark LT, 9/2007

J10 CHECK FOR IWE ENGAGEMENT
• NOTE: The engine must be at idle during the following steps to
supply vacuum for IWE engagement/disengagement.
Start the engine and allow to idle.
• Rotate the LH front tire one revolution forward and one Yes
revolution backward while observing the LH front halfshaft and CHECK that all driveline fasteners are
U-joint. present and tightened to specification.
• Rotate the RH front tire one revolution forward and one REFER to Section 205-00 for further
revolution backward while observing the RH front halfshaft and diagnosis of the front axle.
U-joint. No
• Did the front driveshafts rotate? GO to Pinpoint Test I.
J11 CHECK THE TRANSFER CASE SHIFT TO 2H
circuit.
• Monitor the transfer case contact plate switch A (PLATE A), B
(PLATE B), C (PLATE C) and D (PLATE D) PIDs for the
contact plate position with the MSS in the 2H position.

4H Mode OPEN CLOSED CLOSED OPEN
4L Mode OPEN CLOSED OPEN CLOSED
Yes
• Does the 4X4 control module (PCM) PID and instrument End the active command. GO to J12.
cluster (IC) indicator lamp indicate that vehicle shifted into No
2H? End the active command. GO to J16.
J12 CHECK FOR IWE DISENGAGEMENT
revolution backward while observing the LH front halfshaft and
U-joint.
• Rotate the RH front tire one revolution forward and one Yes
revolution backward while observing the RH front halfshaft and GO to Pinpoint Test I.
U-joint. No
• Did either front axle shaft and U-joint rotate? GO to J13.
J13 CHECK FOR TRANSFER CASE DISENGAGEMENT
• With the vehicle in NEUTRAL, position it on a hoist. Refer to Yes
Section 100-02. The system is functioning correctly.
• Rotate the rear driveshaft while observing the front driveshaft. No
• Does the front driveshaft rotate? GO to J14.
J14 CHECK THE TRANSFER CASE CONTACT PLATE POSITION
PIDs
• NOTE: If plate position was checked with the MSS in a different
position, re-enter DataLogger and deselect then reselect the
contact plate power (PLATE PWR) active command.
Using the active command PLATE PWR energize the transfer
plate switch A (PLATE A), B (PLATE B), C (PLATE C) and D
(PLATE D) PIDs for the contact plate position with the MSS in
the 4H position.
(Continued)
2008 F-150, Mark LT, 9/2007

J14 CHECK THE TRANSFER CASE CONTACT PLATE POSITION
PIDs (Continued)

4L Mode OPEN CLOSED OPEN CLOSED End the active command. GO to J31.
No
• Does the transfer case contact plate PID indicate 4H? End the active command. GO to J15.
J15 CHECK THE TRANSFER CASE SHIFT MOTOR OPERATION
• Remove the transfer case shift motor from the transfer case,
leaving the wiring connector connected.
• Observe the transfer case shift motor while switching the MSS Yes
from 2H to 4H. GO to J31.
• Does the transfer case shift motor rotate from the 2H No
position to the 4H position? GO to J16.
J16 CHECK CIRCUITS 770 (WH), 771 (VT/YE), 772 (LB), 778 (OG)
AND 782 (BN/WH) FOR AN OPEN
• Disconnect: Transfer Case C350.
• Disconnect: 4X4 Control Module (PCM) C175T.
• Measure the resistance of the following circuits between 4X4
control module (PCM) C175T, harness side and transfer case
C350, harness side:
Circuit C175T Pin C350 Pin

770 (WH) 6 5
771 (VT/YE) 7 1
772 (LB) 8 9
778 (OG) 9 13
782 (BN/WH) 46 10
Yes
GO to J17.
No
• Are the resistances less than 5 ohms? REPEAT the self-test.
AND 782 (BN/WH) FOR A SHORT TO VOLTAGE
• Measure the voltage between the following circuits at 4X4
control module (PCM) C175T, harness side and ground:
(Continued)
2008 F-150, Mark LT, 9/2007

AND 782 (BN/WH) FOR A SHORT TO VOLTAGE (Continued)
Circuit C175T Pin

770 (WH) 6
771 (VT/YE) 7
772 (LB) 8
778 (OG) 9
782 (BN/WH) 46
Yes
No
AND 782 (BN/WH) FOR A SHORT TO GROUND
• Measure the resistance between the following circuits at 4X4
control module (PCM) C175T, harness side and ground:
Circuit Pin
770 (WH) 6
771 (VT/YE) 7
772 (LB) 8
778 (OG) 9
782 (BN/WH) 46
(Continued)
2008 F-150, Mark LT, 9/2007

AND 782 (BN/WH) FOR A SHORT TO GROUND (Continued)
Yes
GO to J19.
No
• Are the resistances greater than 10,000 ohms? REPEAT the self-test.
J19 CHECK THE SHIFT MOTOR FOR AN INTERNAL SHORT TO
GROUND
• Measure the resistance between shift motor C350 pins 1, 5, 9,
10, 13 component side and ground.
Yes
GO to J20.
No
INSTALL a new transfer case shift motor.
CLEAR the DTCs. REPEAT the self-test,
• Is the resistance greater than 10,000 ohms? then GO to J30.
J20 CHECK CIRCUITS 785 (BK/LG) AND 786 (RD) FOR POWER
DURING CLOCKWISE RELAY CONTROL (CW RELAY) AND
TRANSFER CASE SHIFT RELAY (L2H) COUNTERCLOCKWISE
(CCW RELAY) ACTIVE COMMANDS
(Continued)
2008 F-150, Mark LT, 9/2007

J20 CHECK CIRCUITS 785 (BK/LG) AND 786 (RD) FOR POWER
DURING CLOCKWISE RELAY CONTROL (CW RELAY) AND
TRANSFER CASE SHIFT RELAY (L2H) COUNTERCLOCKWISE
(CCW RELAY) ACTIVE COMMANDS (Continued)
• Enter the CW RELAY command ON and OFF and measure
the voltage between transfer case C350-15, circuit 786 (RD),
harness side and ground. Enter the CCW RELAY command
ON and OFF and measure the voltage between transfer case
C350-14, circuit 785 (BK/LG), harness side and ground.
Yes
INSTALL a new transfer case shift motor.
CLEAR the DTCs. REPEAT the self-test,
then GO to J30.
• Are the voltages 9 volts or greater on the circuit being No
commanded? GO to J21.
J21 CHECK THE CLOCKWISE/COUNTERCLOCKWISE RELAY
CIRCUITS FOR VOLTAGE
• Disconnect: Clockwise Relay.
• Disconnect: Counterclockwise Relay.
• Measure the voltage between clockwise motor relay pin 86 and
pin 87, circuit 704 (DG/LG), harness side and ground; and
between counterclockwise motor relay pin 86 and pin 87, circuit
704 (DG/LG), harness side and ground.
Yes
GO to J22.
No
• Is the voltage 9 volts or greater? REPEAT the self-test.
(Continued)
2008 F-150, Mark LT, 9/2007

J22 CHECK THE CLOCKWISE/COUNTERCLOCKWISE RELAY
GROUND CIRCUITS
• Measure the resistance between clockwise motor relay pin 87a,
circuit 57 (BK), harness side and ground; and between
counterclockwise motor relay pin 87a, circuit 57 (BK), harness
side and ground.
Yes
GO to J23.
No
J23 CHECK CLOCKWISE/COUNTERCLOCKWISE RELAY CONTROL
CIRCUITS USING THE CLOCKWISE RELAY CONTROL
(CW RELAY) AND TRANSFER CASE SHIFT RELAY (L2H)
COUNTERCLOCKWISE (CCW RELAY) ACTIVE COMMANDS
• Using the scan tool, command the CW RELAY (OFF to ON)
and CCW RELAY (ON to OFF).
• Measure the resistance between clockwise relay C1440-85,
circuit 975 (BN/YE) harness side and ground; and between
counterclockwise relay C1441-85, circuit 976 (OG) harness side
and ground when commanded to move clockwise (OFF to ON)
or counterclockwise (ON to OFF).
Yes
• Is pin 1 of the appropriate relay grounded (5 ohms or less GO to J24.
resistance) when the shift motor is commanded to move in No
that direction? GO to J27.
J24 CHECK CIRCUIT 785 (BK/LG) AND CIRCUIT 786 (RD) FOR AN
OPEN
(Continued)
2008 F-150, Mark LT, 9/2007

J24 CHECK CIRCUIT 785 (BK/LG) AND CIRCUIT 786 (RD) FOR AN
OPEN (Continued)
• Measure the resistance between transfer case C350-14, circuit
785 (BK/LG), harness side and counterclockwise motor relay pin
30, circuit 785 (BK/LG), harness side; and between transfer case
C350-15, circuit 786 (RD), harness side and clockwise motor
relay pin 30, circuit 786 (RD), harness side.
Yes
GO to J25.
No
J25 CHECK CIRCUIT 785 (BK/LG) AND CIRCUIT 786 (RD) FOR
SHORT TO POWER
• Measure the voltage between transfer case C350-14, circuit 785
(BK/LG), harness side and ground; and between transfer case
C350-15, circuit 786 (RD), harness side and ground.
Yes
No
SHORT TO GROUND
(Continued)
2008 F-150, Mark LT, 9/2007

SHORT TO GROUND (Continued)
785 (BK/LG), harness side and ground; and between the
transfer case C350-15, circuit 786 (RD), harness side and
ground.
Yes
INSTALL a new relay. CLEAR the DTCs.
No
J27 CHECK THE RELAY CONTROL CIRCUIT 975 (BN/YE) AND
CIRCUIT 976 (OG) FOR AN OPEN
• Measure the resistance between 4X4 control module (PCM)
C175B-14, circuit 975 (BN/YE), harness side and clockwise
motor relay pin 85, circuit 975 (BN/YE), harness side; and
between 4X4 control module (PCM) C175B-15, circuit 976
(OG), harness side and counterclockwise motor relay pin 85,
circuit 976 (OG), harness side.
Yes
GO to J28.
No
J28 CHECK CIRCUIT 975 (BN/YE) AND CIRCUIT 976 (OG) FOR A
SHORT TO GROUND
(Continued)
2008 F-150, Mark LT, 9/2007

SHORT TO GROUND (Continued)
• Measure the resistance between 4X4 control module (PCM)
C175B-14, circuit 975 (BN/YE), harness side and ground; and
between 4X4 control module (PCM) C175B-15, circuit 976 (OG),
harness side and ground.
Yes
GO to J29.
No
SHORT TO POWER
• Disconnect: Clockwise Relay.
• Disconnect: Counterclockwise Relay.
• Measure the voltage between 4X4 control module (PCM)
C175B-14, circuit 975 (BN/YE), harness side and ground; and
between 4X4 control module (PCM) C175B-15, circuit 976 (OG),
Yes
No
J30 ATTEMPT TO DUPLICATE THE CONCERN
• Inspect and, if necessary, clean the 4X4 control module (PCM) INSTALL a new 4X4 control module
and clockwise/counterclockwise relays and connectors. (PCM). REFER to Section 303-14.
• Drive the vehicle and attempt to duplicate the concern. REPEAT the self-test.
• Is the concern still present? No
CLEAR the DTCs. REPEAT the self-test.
(Continued)
2008 F-150, Mark LT, 9/2007

J31 SHIFT THE TRANSFER CASE TO 4H MANUALLY
• Remove the transfer case shift motor from the transfer case. Yes
• Using a suitable wrench, rotate the shift cam to the 4H position. GO to J32.
• Rotate the rear driveshaft and watch the front driveshaft. No
• Does the transfer case shift to 4H and the front driveshaft REPAIR the transfer case. REFER to
rotates? Section 308-07B.
J32 CHECK THE TORQUE REQUIRED TO SHIFT THE TRANSFER
CASE
• Rotate the shift cam by hand through 4L, 4H and 2H positions. Yes
• Measure the torque required to perform the shift. GO to J33.
• Is the torque required to shift 45 Nm (33 lb-ft) or less? No
REPAIR the transfer case. REFER to
Section 308-07B.
J33 SHIFT THE TRANSFER CASE TO 2H MANUALLY
• Rotate the shift cam to the 2H position. Yes
• Rotate the rear driveshaft and watch the front driveshaft. GO to J34.
• Does the transfer case shift to 2H and the front driveshaft No
does not rotate? REPAIR the transfer case. REFER to
Section 308-07B.
J34 SHIFT THE TRANSFER CASE TO 4L MANUALLY
• Rotate the shift cam by hand to the 4L position. Yes
• Rotate the rear driveshaft and watch the front driveshaft. INSTALL a new transfer case shift motor,
• Does the transfer case shift to 4L and the front driveshaft then GO to J30.
rotates? No
REPAIR the transfer case. REFER to
Section 308-07B.
Pinpoint Test K: The Vehicle Does Not Shift This pinpoint test is intended to diagnose
Between 4H and 4L Modes Correctly the following:
Refer to Wiring Diagrams Cell 34, Four-Wheel • Transmission neutral switch
Drive System for schematic and connector • ABS wheel speed inputs
information.
• Controller area network (CAN) communication
Normal Operation network
The high-low shift occurs when the reduction shift
fork moves the high-low collar to lock the planetary
gear set to the output shaft. The torque transmitted
through the sun gear from the input shaft turns the
front planetary gear set assembly. The front
planetary gear set assembly, now engaged, provides
transfer case speed reduction. Certain criteria, such
as vehicle speed and transmission range (TR)
selection must be met before this shift can occur.
Systematically check the necessary inputs and
outputs of the 4X4 control module (PCM),
components of the transfer case, integrated wheel
end (IWE) components and halfshafts.
• DTC C1729 Transfer Case Unable to Transition
Between 4WD HIGH and 4WD LOW — Failure
to reach designated motor position within allotted
time after multiple retries.
2008 F-150, Mark LT, 9/2007

PINPOINT TEST K: THE VEHICLE DOES NOT SHIFT BETWEEN 4H AND 4L MODES CORRECTLY
K1 CHECK FOR DTCs
• Key in ON position. If DTC 1729 is present, GO to K2.
• Carry out the 4X4 control module on-demand self test. No
• Are DTCs retrieved? GO to Pinpoint Test J
K2 CHECK THE TWO WHEEL DRIVE (2WD) TO FOUR WHEEL
DRIVE (4WD) SHIFT
• Drive the vehicle and shift from 2WD to 4WD. Yes
• Does the vehicle shift between 2WD and 4WD correctly? GO to K3.
No
GO to Pinpoint Test J.
K3 CHECK THE 4H TO 4L SHIFT
• Drive the vehicle and shift MSS from 4H to 4L. Yes
• Does the transfer case shift from 4H to 4L correctly and the Transmission neutral drag is excessive.
complaint is related to a clunk noise during the shift? REFER to Section 307-01 for transmission
diagnosis.
No
GO to K4.
K4 CHECK THE NEUTRAL SAFETY SWITCH (NTRL SW) AND
ABS MODULE WHEEL SPEED PIDs
• A. Monitor the NTRL SW PID while shifting the transmission
through gear ranges.
DataLogger — ABS Module. If all 5 PIDs are accurate, GO to Pinpoint
• B. Monitor the wheel speed PIDs: Test J.
— Left Front Wheel Speed Sensor (LF WSPD) No
— Left Rear Wheel Speed Sensor (LR WSPD) A. REFER to Section 307-01 for further
— Right Front Wheel Speed Sensor (RF WSPD) diagnosis of the TR sensor and the CAN
— Right Rear Wheel Speed Sensor (RR WSPD) communication network.
• A. Does the NTRL SW PID indicate NEUTRAL when the B. REFER to Section 206-09 for further
transmission is shifted to NEUTRAL? diagnosis of the ABS system and the CAN
B. Do the wheel speed PIDs indicate 0 km/h (0 mph)? communication network.
Pinpoint Test L: 4WD Does Not Engage at Normal Operation

Speed Correctly When the operator selects 4H mode, the 4X4
Refer to Wiring Diagrams Cell 34, Four-Wheel control module (PCM) engages a clutch for
Drive System for schematic and connector approximately 5 seconds to synchronize the front
information. and rear driveshafts allowing a mechanical
engagement of the transfer case. The 4X4 control
module (PCM) also removes the ground path from
the integrated wheel ends (IWEs) solenoid, which
removes vacuum from the IWEs, allowing them to
engage the front axle shaft. Systematically check the
necessary inputs and outputs at the 4X4 control
module (PCM), internal components of the transfer
case, IWE components and drive axles.

P1824 — 4WD Drive Clutch Relay Circuit Failure Hard short to ground on clutch output line sensed by 4X4
control module (PCM) C175T pin 49.
P1826 — 4WD Low Clutch Relay Circuit to Battery Short to battery on clutch output line sensed by 4X4
P1827 — 4WD Low Clutch Relay Circuit to Ground Soft short to ground on clutch output line sensed by 4X4
2008 F-150, Mark LT, 9/2007

This pinpoint test is intended to diagnose • 4X4 control module (PCM)
the following:
• Front axle assembly
• Transfer case clutch coil
• Transfer case
PINPOINT TEST L: 4WD DOES NOT ENGAGE AT SPEED CORRECTLY
L1 RETRIEVE DTCs
• Key in ON position. If DTC 1826, GO to L15. If DTC 1824
• Carry out the 4X4 control module self-test. and/or 1827, GO to L10. For all other
• Are any DTCs retrieved? DTCs, GO to Symptom Chart.
No
GO to L2.
L2 CHECK 4H ENGAGEMENT AT REST
• Switch the mode select switch (MSS) from 2H to 4H. Yes
• Drive the vehicle and in turns and check for wind-up. GO to L3.
• Does 4H engage at rest correctly? No
L3 CHECK 2H TO 4H SHIFT AT SPEED
• Drive the vehicle and carry out a 2H to 4H shift while driving
approximately at 16 km/h (10 mph).
• Stop the vehicle, shift to 2H, drive the vehicle and carry out a Yes
2H to 4H shift while driving at approximately 64 km/h (40 mph). GO to Pinpoint Test I.
• Does 4H engage correctly (or much better) at 16 km/h (10 No
mph) than at 64 km/h (40 mph)? GO to L4.
L4 CHECK THE TRANSFER CASE CLUTCH COIL RELEASE USING
PWM OUTPUT CONTROL COMMAND #1 (CLCH SOL)
• Using the scan tool, command the CLCH SOL transfer case
clutch to 98%.
Section 100-02.
• Remove the transfer case shift motor from the transfer case,
leaving the electrical connector connected.
• Using a suitable wrench, shift the transfer case shift cam to 2H. Yes
• Rotate the rear driveshaft while observing the front driveshaft. GO to L5.
• Does the front driveshaft rotate when the rear driveshaft is No
rotated at 98% clutch capacity 30 Nm (22 lb-ft)? GO to L8.
L5 CHECK THE TRANSFER CASE CLUTCH COIL RELEASE USING
• Using the scan tool, command the CLCH SOL transfer case
clutch to 0%. Yes
• Does the front driveshaft rotate when the rear driveshaft is No
rotated? GO to L6.
L6 CHECK THE TRANSFER CASE SYNCHRONIZATION (ON A
HOIST)
• Key in START position.
• Place the transmission range (TR) selector in DRIVE and
increase speed to between 16 km/h (10 mph) and 24 km/h (15 Yes
mph). GO to L7.
• While observing the front driveshaft, switch the MSS to 4H. No
• Did the front driveshaft start to spin? GO to L16.
(Continued)
2008 F-150, Mark LT, 9/2007

PINPOINT TEST L: 4WD DOES NOT ENGAGE AT SPEED CORRECTLY (Continued)
L7 CHECK THE TRANSFER CASE DISENGAGEMENT
• Shift to 2H. Yes
• Did the front driveshaft rotate? No
GO to Pinpoint Test I.
L8 CHECK CIRCUIT 779 (BN) FOR VOLTAGE USING PWM
OUTPUT CONTROL COMMAND #1 (CLCH SOL)
• With active command CLCH SOL still at 98%, measure the
voltage between transfer case C350-16, circuit 779 (BN),
harness side and the transfer case housing.
Yes
End the active command. INSTALL a new
transfer case synchronization clutch.
REFER to Section 308-07B. CLEAR the
No
• Is the voltage greater than 9 volts? GO to L9.
L9 CHECK THE TRANSFER CASE CHASSIS GROUND USING PWM
• With active command CLCH SOL still at 98%, measure the
voltage between transfer case C350-16, circuit 779 (BN),
harness side and chassis ground.
Yes
End the active command. REPAIR the
transfer case ground connection between
the transfer case and the chassis. CLEAR
the DTCs. REPEAT the self-test.
No
• Is the voltage greater than 9 volts? End the active command. GO to L10.
L10 CHECK CIRCUIT 779 (BN) FOR A SHORT TO GROUND
(Continued)
2008 F-150, Mark LT, 9/2007

L10 CHECK CIRCUIT 779 (BN) FOR A SHORT TO GROUND
(Continued)
779 (BN), harness side and ground.
Yes
GO to L11.
No
• Is the resistance greater than 10,000 ohms? REPEAT the self-test.
L11 CHECK CIRCUIT 779 (BN) FOR AN OPEN
779 (BN), harness side and 4X4 control module (PCM)
C175T-49, circuit 779 (BN), harness side.
Yes
GO to L12.
No
L12 CHECK CIRCUIT 92 (LB/YE) FOR A SHORT TO POWER
• Measure the voltage between transfer case C350-12, circuit 92
(LB/YE), harness side and ground.
Yes
No
• Is any voltage present? GO to L13.
(Continued)
2008 F-150, Mark LT, 9/2007

L13 CHECK CIRCUIT 92 (LB/YE) FOR AN OPEN
92 (LB/YE), harness side and the 4X4 control module (PCM)
C175T-48, circuit 92 (LB/YE), harness side.
Yes
GO to L16.
No
L14 CHECK CIRCUIT 779 (BN) FOR VOLTAGE USING PWM
• With active command CLCH SOL greater than 10%, measure
the voltage between transfer case C350-16, circuit 779 (BN),
Yes
End active command. GO to L15.
No
End active command. INSTALL a new
transfer case synchronization clutch.
REFER to Section 308-07B. CLEAR the
• Is any voltage present? DTCs. REPEAT the self-test.
L15 CHECK CIRCUIT 779 (BN) FOR A SHORT TO POWER USING
(Continued)
2008 F-150, Mark LT, 9/2007

L15 CHECK CIRCUIT 779 (BN) FOR A SHORT TO POWER USING
(Continued)
• With active command CLCH SOL at 0%, measure the voltage
between transfer case C350-16, circuit 779 (BN), harness side
and ground.
Yes
No
• Is any voltage present? GO to L16.
L16 CHECK FOR CORRECT 4X4 CONTROL MODULE (PCM)
OPERATION
• Disconnect all 4X4 control module (PCM) connectors. INSTALL a new 4X4 control module
• Check for: (PCM). REFER to Section 303-14.
— corrosion. REPEAT the self-test.
— pushed-out pins. No
• Connect all 4X4 control module (PCM) connectors and make The system is operating correctly at this
sure they are seated correctly. time. Concern may have been caused by
• Operate the system and verify the concern is still present. a loose or corroded connector. CLEAR the
• Is the concern still present? DTCs. REPEAT the self-test.
Pinpoint Test M: The Transfer Case Jumps This pinpoint test is intended to diagnose
Out of Gear the following:
Normal Operation • Integrated wheel end (IWE) vent line(s)
Once the four wheel drive (4WD) system engages • Mode select switch (MSS)
the user selected mode, that mode should be • Transfer case
maintained. If the 4WD system does not stay in the
selected position systematically check the 4WD
system components.
PINPOINT TEST M: THE TRANSFER CASE JUMPS OUT OF GEAR
M1 CHECK FOR OBSTRUCTED IWE VENT LINES
Section 100-02.
• NOTE: The IWE vent port is the smaller of the 2 vacuum ports.
Disconnect the LH IWE line from the vent port. Yes
• Attach a vacuum pump to the IWE vent line. INSTALL new IWE vent lines as
• Attempt to draw and hold a vacuum. Repeat Steps 1-3 for the necessary.
RH side of the vehicle. No
• Can a vacuum be held on either IWE vent line? GO to M2.
M2 VERIFY THE CONCERN
• Drive the vehicle and attempt to duplicate the concern. Yes
• Is the concern an uncommanded range shift (in or out of GO to M5.
low range)? No
GO to M3.
(Continued)
2008 F-150, Mark LT, 9/2007

PINPOINT TEST M: THE TRANSFER CASE JUMPS OUT OF GEAR (Continued)
M3 CHECK THE MSS POSITION MONITORING THE 4WD SWITCH
STATUS (4WDINP SW) PID
• Drive the vehicle.
• Dynamically monitor the MSS 4WDINP SW PID while driving Yes
the vehicle in each shift position. GO to M4.
• Does the MSS 4WDINP SW PID always agree with the No
switch position? GO to Pinpoint Test J.
M4 CHECK FOR DTCs
• Carry out the 4X4 control module on-demand self test. Yes
• Are DTCs present? REFER to the 4X4 Control Module (PCM)
DTC Chart.
No
GO to Pinpoint Test O.
M5 CHECK THE 4WD INDICATORS
• Stop the vehicle.
• Transmission in NEUTRAL.
• Depress the brake pedal. Yes
• Observe the 4WD indicators in the instrument cluster (IC) while GO to M3.
cycling through each MSS position. No
• Do the 4WD indicators match MSS switch positions? GO to M6.
M6 CHECK FOR DTCs
DataLogger — 4X4 Control Module. REFER to the 4X4 Control Module (PCM)
• Transmission in PARK. DTC Chart.
• Release the brake pedal. No
• Carry out the 4X4 control module on-demand self test. CHECK the transfer case fluid level.
• Are DTCs present? REFER to Section 308-07B. If the fluid
level is OK, CHECK for internal transfer
case faults. REFER to Section 308-07B.
Pinpoint Test N: Straightline Driveline This pinpoint test is intended to diagnose

Wind-up the following:
Normal Operation • Unmatched tire sizes
In order for the four wheel drive (4WD) system to • Unequal amounts of tire wear
function correctly, tires and wheels must be the • Unequal tire inflation pressures
same size, be in good condition, and the front and
rear axle ratios must match. • Unmatched front and rear axle ratios
PINPOINT TEST N: STRAIGHTLINE DRIVELINE WIND-UP

NOTE: 4X4 high/low (4H/4L) is not intended for driving on hard/dry surfaces.
N1 VERIFY THE CONCERN
• Drive the vehicle and shift from 2H to 4H. There should be Yes
minimal wind-up in 4H mode during straight line maneuvers, GO to N2.
(wind-up in turns is normal; 4X4 high/low is not intended for No
driving on hard/dry surfaces). RETURN the vehicle to the customer.
• Is excessive wind-up present? ADVISE about correct 4WD system
operation and normal vehicle behavior.
(Continued)
2008 F-150, Mark LT, 9/2007

PINPOINT TEST N: STRAIGHTLINE DRIVELINE WIND-UP (Continued)
N2 CHECK FOR MATCHING WHEEL AND TIRE SIZES
• Check the wheel and tire sizes. Yes
• Do the 4 wheel and tire sizes match? GO to N3.
No
ADVISE the customer that 4WD systems
require 4 matched, correctly inflated,
correctly maintained tires to operate
correctly.
N3 CHECK TIRE WEAR
• Check each of the 4 tires for wear. Yes
• Are the 4 tires worn evenly? GO to N4.
No
correctly rotated tires to operate correctly.
N4 CHECK TIRE INFLATION PRESSURE
• Check the inflation pressure in each tire. Refer to vehicle Yes
certification label. GO to N5.
• Are the tire inflation pressures correct? No
ADJUST the tire pressure as necessary.
TEST the vehicle for normal operation.
correctly maintained tires to operate
correctly.
N5 CHECK THE FRONT AND REAR AXLE RATIOS
• Check that front and rear axle ratios match. Refer to Section Yes
205-03. RETURN the vehicle to the customer and
• Do the front and rear axle ratios match? ADVISE about correct 4WD usage and
normal vehicle behavior.
No
CHECK the vehicle identification label.
INSTALL the correct axle(s). REFER to
Section 205-00.
Pinpoint Test O: Electronic Shift on the Fly This pinpoint test is intended to diagnose
(ESOF) Functional Test the following:
Normal Operation • Transfer case and related components
When operating in four wheel drive (4WD), the • IWE and related components
transfer case and both integrated wheel ends (IWEs) • Wheel/tire assemblies
are locked. When in 4X4 low (4L), the transfer case
low range gear set provides an additional 2.64 gear
reduction. When operating in two wheel drive
(2WD), the transfer case and both IWEs are
unlocked.
PINPOINT TEST O: ELECTRONIC SHIFT ON THE FLY (ESOF) FUNCTIONAL TEST
NOTE: 4X4 high/low (4H/4L) is not intended for driving on hard/dry surfaces.
O1 CHECK FOR 4WD INDICATOR PROVE OUT
• Key in ON position. GO to O2.
• Do the 4WD indicators illuminate at prove out? No
CHECK the instrument cluster (IC) for
faults. REFER to Section 413-01.
(Continued)
2008 F-150, Mark LT, 9/2007

PINPOINT TEST O: ELECTRONIC SHIFT ON THE FLY (ESOF) FUNCTIONAL TEST (Continued)
O2 CHECK 2WD OPERATION
• Transmission in NEUTRAL. Yes
• Switch the mode select switch (MSS) to 2H. GO to O5.
• Do the 4WD indicators turn off? No
GO to O3.
O3 CHECK FOR DTCs
• Transmission in PARK. Yes
• Connect the scan tool. REFER to the 4X4 Control Module (PCM)
• Carry out the 4X4 control module on-demand self test. DTC Chart for diagnosis.
• Are DTCs retrieved? No
GO to O4.
O4 CHECK FOR WIND-UP IN 2H
• Drive the vehicle on a dry, hard surface while executing turns. Yes
• Is wind-up present in turns? GO to Pinpoint Test K.
No
GO to Pinpoint Test P.
• Is wind-up present in turns? REPAIR the transfer case. REFER to
Section 308-07B.
No
GO to O6.
O6 CHECK 4H OPERATION
• Does the 4H indicator illuminate correctly? GO to O9.
No
GO to O7.
O7 CHECK FOR DTCs
GO to O8.
• Is wind-up present in turns? GO to Pinpoint Test P.
No
O9 CHECK FOR 4H WIND-UP
• Drive the vehicle on a dry, hard surface. Yes
• Is straightline wind-up present? GO to Pinpoint Test N.
No
GO to O10.
O10 CHECK 4H WIND-UP IN TURNS
• Drive the vehicle in 4H while turning. Yes
• Is wind-up present in turns? GO to O11.
No
O11 CHECK 4L OPERATION
• Bring the vehicle to a stop with the transmission in NEUTRAL Yes
and switch the MSS to 4L. GO to O14.
• Does the 4X4 LOW indicator illuminate correctly? No
GO to O12.
(Continued)
2008 F-150, Mark LT, 9/2007

O12 CHECK FOR DTCs
GO to O13.
O13 CHECK FOR WIND-UP IN 4L
• Is wind-up present in turns? GO to Pinpoint Test P.
No
GO to Pinpoint Test K.
O14 CHECK FOR 4L WIND-UP IN TURNS
• Is wind-up present and 4L functioning? GO to O15.
No
CHECK for 4X4 control module DTCs.
REFER to the Inspection and Verification
procedure in this section. If no DTCs are
present, GO to Pinpoint Test K.
O15 CHECK 4L TO 2H SHIFT
• With the vehicle at a stop and transmission in NEUTRAL, switch Yes
the MSS from 4L to 2H. GO to O18.
• Do the 4WD indicators turn off? No
GO to O16.
O16 CHECK FOR DTCs
GO to O17.
• Drive the vehicle on a dry, hard surface while executing turns. GO to Pinpoint Test K.
• Is wind-up present in turns? No
GO to Pinpoint Test P.
O18 CHECK FOR TRANSFER CASE DISENGAGEMENT
• With the vehicle in NEUTRAL, position it on a hoist. Refer to Yes
Section 100-02. REFER to Section 308-07B.
• Rotate the rear driveshaft while observing the front driveshaft. No
• Does the front driveshaft rotate? GO to O19.
O19 CHECK FOR LH AND RH IWE DISENGAGEMENT
NOTE: The engine must be at idle during the following steps to
supply vacuum for IWE engagement/disengagement.
• Start the engine and allow to idle.
revolution backward while observing the LH front halfshaft and
U-joint.
• Rotate the RH front tire one revolution forward and one Yes
revolution backward while observing the RH front halfshaft and GO to Pinpoint Test I.
U-joint. No
• Does the LH or RH front halfshaft rotate? GO to O20.
O20 CHECK FOR IWE VACUUM LEAKS
• Using a vacuum pump, apply 508 mm (20 in) Hg of vacuum to Yes
the IWE apply vacuum circuit. CHECK the IWE and related components
• Observe the vacuum reading. for leaks. GO to Pinpoint Test I.
minute? GO to O21.
(Continued)
2008 F-150, Mark LT, 9/2007

O21 CHECK 2H TO 4H SHIFT AT SPEED ABOVE 32 KM/H (20 MPH)
• Drive the vehicle on the road and shift from 2H to 4H while The 4WD system is functioning correctly.
driving above 32 km/h (20 mph). No
• Does the transfer case shift to 4H satisfactorily? GO to Pinpoint Test L.
Pinpoint Test P: The Instrument Cluster (IC) This pinpoint test is intended to diagnose
4X4 LOW and 4X4 HI Indicators Do Not the following:
Operate Correctly/Do Not Operate • Four wheel drive (4WD) system fault
Refer to Wiring Diagrams Cell 34, Four Wheel • Wiring, terminals or connectors
Drive System for schematic and connector
information. • 4X4 control module (PCM)
• IC
Normal Operation
The 4H indicator status is transmitted to the
instrument cluster (IC) from the 4X4 control module
(PCM) through the controller area network (CAN),
circuits 1827 (WH/LG) and 1828 (PK/LG). A
steady indicator displays whether the vehicle is in
4L or 4H, according to the driver selection.
Flashing 4H and 4L indicators is an indication that
the IC has lost communication with the 4X4 control
module (PCM). For information about CAN, refer
to Section 418-00.
PINPOINT TEST P: THE INSTRUMENT CLUSTER (IC) 4X4 LOW AND 4X4 HI INDICATORS DO NOT
OPERATE CORRECTLY/DO NOT OPERATE
P1 CHECK THE 4WD INDICATOR PROVE-OUT
• Key in ON position. GO to P2.
• Do the 4WD indicators prove out correctly? No
CHECK the IC for faults. REFER to
Section 413-01.
P2 CHECK FOR DTCs
• Carry out the 4X4 control module on-demand self test. REFER to the 4X4 Control Module (PCM)
• Are DTCs present? DTC Chart for diagnosis.
No
GO to P3.
P3 CHECK THE 4WD INDICATORS IN 2H
• Switch the mode select switch (MSS) to 2H. Yes
• Do any of the 4WD indicator(s) illuminate? GO to P5.
No
GO to P4.
P4 CHECK THE INDICATORS IN 4H
• Monitor the 4X4 HI IC indicator. GO to P6.
• Does only the 4X4 HI IC indicator illuminate? No
GO to P7.
P5 CHECK THE PIDs IN 2H
(Continued)
2008 F-150, Mark LT, 9/2007

OPERATE CORRECTLY/DO NOT OPERATE (Continued)
P5 CHECK THE PIDs IN 2H (Continued)
circuit.
• Monitor the integrated wheel end (IWE) solenoid IWE SOLST
and 4X4 control module (PCM) transfer case contact plate
switch A (PLATE A), B (PLATE B), C (PLATE C) and D
(PLATE D) PIDs for the contact plate position with the MSS in
the 2H position.

4L Mode OPEN CLOSED OPEN CLOSED Section 413-01.
No
• Do the PIDs indicate that IWE solenoid is energized (or ON) End the active command. GO to Pinpoint
and that the motor is in the 2H position? Test J.
P6 CHECK THE INDICATORS IN 4L
• With the vehicle at a stop and transmission in NEUTRAL, switch Yes
the MSS to 4L. The 4WD indicators are operating
• Monitor the 4X4 LOW IC indicator. correctly. CARRY OUT the Electronic Shift
• Does only the 4X4 LOW IC indicator illuminate? on the Fly (ESOF) Functional Test. GO to
Pinpoint Test O.
No
GO to P8.
P7 CHECK THE PIDs IN 4H
• Monitor the integrated wheel ends solenoid status
(IWE SOLST) and transfer case contact plate switch A
(PLATE A), B (PLATE B), C (PLATE C) and D (PLATE D)
PIDs for the contact plate position with the MSS in the 4H
position.

No
• Do the PIDs indicate that IWE solenoid is de-energized (or End the active command. GO to Pinpoint
OFF) and that the motor is in 4H position? Test J.
P8 CHECK THE PIDs IN 4L
(Continued)
2008 F-150, Mark LT, 9/2007

OPERATE CORRECTLY/DO NOT OPERATE (Continued)
P8 CHECK THE PIDs IN 4L (Continued)
• Monitor the integrated wheel ends solenoid status
(IWE SOLST) and transfer case contact plate switch A
(PLATE A), B (PLATE B), C (PLATE C) and D (PLATE D)
PIDs for the contact plate position with the MSS in the 4L
position.

No
• Do the PIDs indicate that IWE solenoid is de-energized (or End the active command. GO to Pinpoint
OFF)? Test K.
2008 F-150, Mark LT, 9/2007

Diagnosis and Testing: Four Wheel Drive (4WD) Systems - Electronic Shift

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Diagnosis and Testing: Four Wheel Drive (4WD) Systems - Electronic Shift

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308-07A-1 Four Wheel Drive (4WD) Systems 308-07A-1

DIAGNOSIS AND TESTING

Copyright  2007, Ford Motor Company

4X4 Control Module (PCM) DTC Chart

DTC Description Source Action

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

MSS Contact Plate Position

MSS Contact Plate Position

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

Pinpoint Test J: The Vehicle Does Not Shift Normal Operation

DTC Description Fault Trigger Condition

2008 F-150, Mark LT, 9/2007

This pinpoint test is intended to diagnose • 4X4 control module (PCM)

2008 F-150, Mark LT, 9/2007

MSS Position Resistance

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

MSS Contact Plate Position

2008 F-150, Mark LT, 9/2007

MSS Contact Plate Position

Circuit C175T Pin C350 Pin

2008 F-150, Mark LT, 9/2007

Circuit C175T Pin

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

Pinpoint Test L: 4WD Does Not Engage at Normal Operation

DTC Description Fault Trigger Condition

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

Pinpoint Test N: Straightline Driveline This pinpoint test is intended to diagnose

PINPOINT TEST N: STRAIGHTLINE DRIVELINE WIND-UP

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

2008 F-150, Mark LT, 9/2007

MSS Contact Plate Position

MSS Contact Plate Position

2008 F-150, Mark LT, 9/2007

MSS Contact Plate Position

2008 F-150, Mark LT, 9/2007