TECHNICAL SERVICE BULLETIN 23-2174

[themishmosh]

I just had this done under powertrain warranty. I had the codes and grinding noise when turning backing in and out or making a u-turn and the car also drove lurchy with intermittent disconnecting and reconnecting of front axle AWD. It took about a week to complete and was provided a free rental car. I have 49,700 miles and 8 months left on Powwrtrain Warranty!

Congrats! I feel like this is the biggest liability for 2020-2021s. All the other problems will usually rear it's ugly head during the warranty period but the FADA failure might not. I'm at 85k miles and it still hasn't failed although has leaked 30k miles ago. Now you can rest easy that you don't have a FADA anymore and got rid of the old O-ring as well! We are going to be hearing more and more people with FADA failures in the upcoming years just like the AWD module grounding issues are showing up now. I am also wondering if the FADA oil leak has anything to do with the failures.

 

[brody302V8]

Check out this video on the cause of the rough shifting. Brand new TSB and explanation on the cause.

Unfortunately if out of warranty, this is a customer pay job.. but should be a warranty extension based on a defective design.

There is also a new TSB for the front disconnect shaft that goes through the oil pan. New shaft no longer disconnects the front so you are in 4wd full time. New intermediate shaft without disconnect, the plug gets cut off and trans module gets reprogrammed to not look for the disconnect.

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Will this cause the wheels to get into a bind when turning sharp, since it will be in 4wd all the time

 

[hbalek]

Will this cause the wheels to get into a bind when turning sharp, since it will be in 4wd all the time

I had the TSB performed removing the FADA back in the spring, then had to have the rear diferential and transfer case or PTU replaced, Less than 3 months later I had to have the transfer case replaced again. We'll see how long this holds up. 3 months left on powertrain left and 3 years extended warranty left at 54K miles.

 

[peterk9]

There is also a new TSB for the front disconnect shaft that goes through the oil pan. New shaft no longer disconnects the front so you are in 4wd full time. New intermediate shaft without disconnect, the plug gets cut off and trans module gets reprogrammed to not look for the disconnect.

TSB link and number??

Peter

 

[hbalek]

TSB link and number??

Peter

My problems mentioned above were recently solved. The service tech discovered the RDU installed several months ago had the wrong gear ratio. The proper ratio differential was installed and wheel alignment was performed. Now it drives perrfectly and accelerates smoothly for the first time in many months with no shuddering or vibration at all. I have about 6 weeks left on powertrain warranty!

 

[96eb96]

95-96 Explorers had a vacuum actuated axle disconnect. You could select 2WD mode.
In 1997 it was removed, only 4wd Auto.
Seems history repeats itself!

Seems that should be sealed with Permatex Gear Oil RTV behind the O-ring. I doubt that would leak.

 

[Courtneyhope86]

“AWD - Illuminated Powertrain Malfunction (Wrench) Indicator With DTCs C00A6 And/Or C0631 - Built On Or Before 30-Aug-2021”

Curious if anyone has dealt with this. Apparently Ford’s attempt at this fuel saving feature didn’t work out, with clutch and O-ring seal failures. Implementation of this TSB on AWD vehicles replaces the Front Axle Disconnect Actuator (FADA) with what Ford is calling an intermediate shaft along with reprogramming the transfer case control module. The end result is elimination of the vehicle’s capability to disconnect the front axle, making it a full time AWD drivetrain.
One less drivetrain component to fail isn’t necessarily a bad thing but if you’re in the block of vehicles for this TSB and out of warranty when the original FADA fails the repair bill will be on you. Not holding my breath waiting for Ford to step up and extend warranty on this poorly designed component.

Link to a supporting video:

 

[Courtneyhope86]

I’m currently dealing with this with my 2020 explorer and it’s just awful. Mine had the codes to come up beginning of December 2024 but by the time they got it in at Ford, that then put my mileage over the warranty by 447 miles. Ford is refusing to cover it under warranty so now I’m stuck with a $1600 bill. I just don’t understand if they know there is such a big problem with these then why are they not doing a recall! Just money is all it’s about!

 

[peterk9]

I’m currently dealing with this with my 2020 explorer and it’s just awful. Mine had the codes to come up beginning of December 2024 but by the time they got it in at Ford, that then put my mileage over the warranty by 447 miles. Ford is refusing to cover it under warranty so now I’m stuck with a $1600 bill. I just don’t understand if they know there is such a big problem with these then why are they not doing a recall! Just money is all it’s about!

Welcome to the Forum.
This is a TSB and not a Recall because of the limited number of vehicles having the issue. I believe there are only 4 reports in this thread. Recalls are issued for safety-related issues. It's unfortunate that Ford isn't being somewhat understanding of your issue being only 447 out of warranty. This is one reason I always opt to buy an extended warranty if I plan to keep the vehicle beyond the manufacturer's warranty.

Peter

 

[Rick]

Welcome to the Forum.
This is a TSB and not a Recall because of the limited number of vehicles having the issue. I believe there are only 4 reports in this thread. Recalls are issued for safety-related issues. It's unfortunate that Ford isn't being somewhat understanding of your issue being only 447 out of warranty. This is one reason I always opt to buy an extended warranty if I plan to keep the vehicle beyond the manufacturer's warranty.

Peter

Ours has had the issue and the modification done since I originally posted in this thread. I believe it is a safety related issue when the dash lights up like a Christmas tree telling the operator that multiple systems are not functioning due to the issue.

Not having AWD and AdvanceTrac available in bad weather is a safety issue when the vehicle was originally equipped with it. Malfunctioning Reverse Assist is also a safety issue. Both warnings came up when our axle disconnect went bad.

Our luck has run out at about 50,000 miles

Our 2020 has never been back to the dealership since new. It has an open recall for the backup camera, but since we never had an issue with it we never had it taken care of. After lunch today we got the whole list of warnings, Advance Trac, Reverse Assist, and 4wd. My guess is that we have a...

www.explorerforum.com

AdvanceTrac Feature - Feature Description

Traction Control System - Helps avoid drive-wheel spin and loss of traction by selectively applying the brakes and modifying engine power
Electronic Stability Control - Helps to avoid skids or lateral slides, lateral acceleration, and steering wheel angle
Roll Stability Control - Helps to avoid a vehicle rollover by using a roll-rate sensor, selectively applying brakes, and modifying engine power

 

[frankjanstett]

My FADA failed at 81k miles outside the standard warranty, however my dealer advertises their "Tedd Britt 4 Life" lifetime dealer warranty on the engine, Transmission and thePowertrain. Is the FADA considered to be a Powertrain item?

 

[hbalek]

My FADA failed at 81k miles outside the standard warranty, however my dealer advertises their "Tedd Britt 4 Life" lifetime dealer warranty on the engine, Transmission and thePowertrain. Is the FADA considered to be a Powertrain item?

It was a powertrain repair at Sheehy Gaithersburg. After that repair, I have had transfer case and rear differential fail twice. All under powertrain. I'm out of powertrain but now under 2 more years ESP/Premium. This car is plagued with major mechanical issues.

 

[peterk9]

My FADA failed at 81k miles outside the standard warranty, however my dealer advertises their "Tedd Britt 4 Life" lifetime dealer warranty on the engine, Transmission and thePowertrain. Is the FADA considered to be a Powertrain item?

Welcome to the Forum Frank.

Peter