KEEP THOSE TRANNY’S ROLLING

Introducing Ford’s
Intelligent All-Wheel
Drive System: by Pete Huscher
www.atra.com

D
uring the past three years,
while not working on the
ATRA Technical HotLine,
I’ve been researching four-wheel drive
and all-wheel drive systems for upcom-
ing seminars and EXPOs. In the March
2009 issue of GEARS Magazine, I intro-
duced Chrysler’s Interactive Torque
Management System (ITM 3e). In this
issue we’ll take a look at Ford’s new
Intelligent All-Wheel Drive System.
Ford’s new all-wheel drive systems
are referred to as an Intelligent All-Wheel
Drive System or I-AWD, and are found
in the Ford AWD Escape (figure 1),
Ford AWD Five Hundred (figure 2),
Ford AWD Freestyle (figure 3) or the
Ford AWD Flex (figure 4), to name a
few. These AWD systems are always
active, require no input from the driver,
and don’t have a mode-select switch.
These systems combine transparent, all-
surface operation and are capable of
handling all road conditions, including
street and highway driving, as well as
off-road and winter driving.
The I-AWD system continuously
monitors vehicle conditions and auto-
matically adjusts the torque distribu-
tion between the front and rear wheels.
During normal operation, most of the
torque from the transmission is sent to
the front wheels. If the system detects
wheel slip between the front and rear
wheels, or if you operate the vehicle
under heavy throttle conditions, the
I-AWD system will increase the torque
to the rear wheels to prevent or control
wheel slip.

Figure 4: Ford’s
AWD Flex

20 GEARS September 2009

20pete909.indd 20 8/27/09 2:41:09 PM

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Introducing Ford’s Intelligent All-Wheel Drive System

Ford’s I-AWD system consists of to the rear wheels. tive to tire size differences between
these components: The on-demand coupling unit is all four wheels and isn’t sensitive to
• Transfer case or Power Take- attached to the rear axle, between the being towed with one axle raised off
Off Unit (depending on appli- differential gear and the driveshaft. the ground. The I-AWD system uses
cation) The on-demand coupler consists of a CAN BUS system to communicate
• Rear driveshaft mechanical and hydraulic sections that with the powertrain control module
• Electronic on-demand coupler are driven by the driveshaft (figure 7). (PCM) and the ABS/ESP control mod-
device ule (ABS), and uses inputs from each
• Rear axle The Brains of the I-AWD of these systems to control the AWD
• Coupler device control System system (figure 8).
module, known as the 4WD Depending on the application, the
Control Module (4WDCM) I-AWD System is controlled by the Diagnosing Ford’s I-AWD
• Differential Electronic Module 4WDCM (Ford Flex), the ITCC mod- System
(DEM) or an Intelligent ule (Ford Escape) or the Differential Diagnosing the new Intelligent
Torque Control Coupler Electronic Module (DEM) (Ford Five AWD system is pretty straightforward.
(ITCC) module, depending on Hundred and Freestyle). The main pur- Simply connect a compatible scan tool
application (figure 5). pose of the 4WDCM, the DEM or the to the DLC connector and check for
ITCC module is to control the AWD codes in the PCM and the ABS control
The Heart of the I-AWD function by distributing torque between module. Document all codes received
system the front and rear axles. from each of these modules.
The heart of the Intelligent AWD The I-AWD system isn’t sensi- Before starting your diagnosis of
system is the transfer case or power
take-off unit (PTO) and an elec-
tronically controlled, on-demand
coupler. The transfer case or PTO
is a one-speed gearbox that attaches
to the transaxle. The transfer case
or PTO directs power to the rear
driveshaft through a helical gear
coupled to the transaxle differential
case, a helical idler gear, a helical
ring gear assembly, and a pinion set
(figure 6).
The rear driveshaft transfers
power to the electronic on–demand
coupler, located on the rear differ-
ential, which in turn transfers the
power through the rear differential
Figure 5: I-AWD system components

Figure 6: PTU

22 GEARS September 2009

 the AWD system, be sure to correct all P0606 – ECU short or open cir- P0939 – Hydraulic oil tempera-
codes in the other modules. PCM and cuit. Attempt to clear code P0606. If ture sensor circuit low input. Check
ABS problems can and will interfere code P0606 returns, verify all power rear axle oil temperature sensor circuit.
with the AWD system operation. After and ground voltages are correct at the If circuit is okay, suspect a faulty rear
you’ve corrected any codes in the other DEM connector. If voltages are within axle oil temperature sensor.
modules, access the 4WDCM, DEM specification, replace the DEM. P0940 – Hydraulic oil tempera-
or ITCC module and retrieve codes P0932 – Hydraulic pressure sen- ture sensor circuit high input. Check
from the AWD system. The following sor circuit. Check rear axle oil temper- rear axle oil temperature sensor circuit.
list of codes is what you might find in ature sensor circuit. If circuit is okay, If circuit is okay, suspect a faulty rear
the 4WDCM, the ITCC module, or the suspect a faulty rear axle oil tempera- axle oil temperature sensor.
DEM. ture sensor. P0960 – Pressure control sole-
P0937 – Hydraulic oil tempera- noid A circuit open. Check ABS wheel
Codes for the Differential ture sensor circuit. Check rear axle sensor PIDs to verify the ABS module
Electronic Module oil temperature sensor circuit. If circuit is transmitting the correct wheel speed
• P0562 – System voltage low
• P0563 – System voltage high is okay, suspect a faulty rear axle oil to the DEM. Check for leaks from the
• P0602 – PCM programming error temperature sensor. active
C M on-demand
Y CM MY CYcoupler.
CMY K If no leaks
• P0606 – ECU short or open circuit
• P0932 – Hydraulic pressure sensor circuit
• P0937 – Hydraulic oil temperature sensor circuit
• P0939 – Hydraulic oil temperature sensor circuit low
• P0940 – Hydraulic oil temperature sensor circuit high
• P0960 – PCS A control circuit open
• P0961 – PCS A control circuit range performance
• P0962 – PCS A control circuit low
• P1886 – Oil pressure pump performance
• U0001 – High speed CAM communication fault
• U0121 – Lost communication with ABS module
• U2050 – No valid application for DEM

Codes for the 4WD Control

Module and ITCC Module
• B1317 – Battery voltage high
• B1318 – Battery voltage low
• B1342 – ECU defective
• P1635 – Tire or axle out of range
• P1824 – 4WD clutch relay circuit failure
• P1825 – 4WD clutch relay circuit open
• U0100 – Loss of communication with PCM
• U0121 – Loss of communication with ABS
• U0401 – Invalid data received from PCM
• U0415 – Invalid data received from ABS
• U1900 – CAN communication bus fault

I-AWD System Code

Diagnosis for the DEM
P0562 – System voltage is low.
Check battery and charging system
voltage. Verify all power and ground
voltages are correct at the DEM con-
nector. If system voltage is within spec-
ification, replace the DEM.
P0563 – System voltage is high.
Check battery and charging system
voltage. Verify all power and ground
voltages are correct at the DEM con-
nector. If system voltage is within spec-
ification, replace the DEM.
P0602 – PCM programming
error. Attempt to clear code P0602. If
code P0602 returns, verify all power
and ground voltages are correct at the
DEM connector. If voltages are within
specification, replace the DEM.

GEARS September 2009 23

Introducing Ford’s Intelligent All-Wheel Drive System

are found, check the PCS A circuit. If

the PCS A circuit is okay, replace the
DEM.
P0961 – Pressure control sole-
noid A circuit performance. Check
ABS wheel sensor data to verify the
ABS module is transmitting the cor-
rect wheel speed to the DEM. Check
for leaks from the active on-demand
coupler. If no leaks are found, check
the PCS A circuit. If the PCS A circuit
is okay, replace the DEM.
P0961 – Pressure control sole-
noid A circuit low. Check ABS wheel
sensor data to verify the ABS module
is transmitting the correct wheel speed
to the DEM. Check for leaks from the
active on-demand coupler. If no leaks
are found, check the PCS A circuit. If
the PCS A circuit is okay, replace the
Figure 7: On-Demand coupler attached to rear differential. DEM.
P1889 – Oil pressure pump per-
formance. Install a new active on-
demand coupler oil pump. If code
returns, install updated DEM kit
#4C016, available from your local Ford
dealer.
U0001 – High speed CAN com-
munication error. Check high speed
CAN bus system wiring and connec-
tion. Repair as needed.
U0121 – Loss of communication
with ABS module. Check CAN com-
munication system. Check wiring and
connections. Check ABS module power
and grounds. If CAN system and ABS
module power and grounds are okay,
suspect a faulty ABS module.
Figure 8: The I-AWD system communicates with the PCM & the ABS modules.

Figure 9: 4WDCM connector terminal i.d.

24 GEARS September 2009

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Introducing Ford’s Intelligent All-Wheel Drive System

Figure 10: On-Demand Coupler connector terminal i.d.

U2050 – No valid application for

DEM. Reconfigure the DEM using As-
Built data.

I-AWD System Code

Diagnosis for the 4WDCM
and ITCC Module
1317 – Battery voltage high. Check
battery and charging system operation.
Repair as needed.
B1318 – Battery voltage low. Check
battery and charging system operation.
Repair as needed.
B1342 – ECU defective. Attempt to
AAEQ Gears Ad 1-4 Figure 11: DEM connector
pg 031209:1-17 terminal
AAEQ Gears Ad i.d.
3/12/09 2:31 PM Pageclear
1 code B1342. If code B1342 returns,

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 Figure 12: Ford Five Hundred I-AWD system wiring schematic

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GEARS September 2009 27

Introducing Ford’s Intelligent All-Wheel Drive System

check the 4WDCM power and ground nication system. Check PCM power U1900 – CAN communication
circuits. If the 4WDCM power and and ground circuits. If the CAN com- bus fault. Check CAN communication
ground circuits are good, replace the munication system and the PCM power system, wiring and connections. Repair
4WDCM. and ground circuits are okay, suspect a as needed.
P1635 – Tire or axle out of faulty PCM. I've included figures 9, 10, 11,
acceptable range. Check for correct U0121 – Loss of communication 12, 13 and 14, to help you with your
tire sizes and tire pressure. Check ABS with ABS. Check the CAN commu- diagnosis. Refer to the appropriate ser-
system for wheel speed sensor fault. If nication system. Check ABS module vice manual for your specific vehicle’s
wheel speed sensor fault exists, repair power and ground circuits. If the CAN diagnostic routines.
as needed. communication system and the ABS Well, there you have it: a clos-
P1824 – 4WD clutch relay circuit module power and ground circuits are er look at Ford’s new Intelligent All-
failure. Check 4WD clutch relay cir- okay, suspect a faulty ABS module. Wheel Drive system. With a basic
cuit. Check active on-demand coupler U0401 – Invalid data received understanding of how Ford’s I-AWD
circuits. If the coupler circuits check from PCM. Check data coming from system operates and a quick look at the
out okay, suspect a faulty active on- PCM. Check for data being out of diagnostic routines for this system, you
demand coupler or a faulty 4WDCM. range. Repair as needed. should have no problem keeping those
P1825 – 4WD clutch relay circuit U0415 – Invalid data received trannys rolling.
open. Check 4WD clutch relay circuit. from ABS module. Check data com-
Check active on-demand coupler cir- ing from
cuits. If the coupler circuits check out ABS module.
okay, suspect a faulty active on-demand Check for data
coupler or a faulty 4WDCM. being out of
U0100 – Loss of communication range. Repair
with PCM. Check the CAN commu- as needed.

Figure 13: Ford Escape I-AWD system wiring schematic Figure 14: Ford Flex I-AWD system wiring schematic

28 GEARS September 2009

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