Maverick SOS: 14K Miles, Serious AWD issue.

[Phimosis]

Latest update the dealership is replacing the power transfer unit on monday

Very interesting. So the “binding up” is from AWD always being active because the PTU clutch pack won’t disengage?

If that was the case, the clutch pack in the RDU should also be disengaged, preventing AWD from being always on.

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[Monkeybread72]

The full receipt, sorry for being a bit ignorant I don't know what an rdu is

 

[Phimosis]

The full receipt, sorry for being a bit ignorant I don't know what an rdu is

The RDU is the rear drive unit, ie rear differential. They say they inspected the rear axle oil/drain plug and it had excess metal and they could see damaged gears through the oil drain hole. Then they replaced the rear axle. That is the RDU. They also noted the left CV axle was seized into the differential carrier, so they replaced that too.

Then it was still binding up when turning, so you had them re-evaluate and with a FRDS scan tool hooked up to the car, they could see that the awd was indeed staying engaged. They then tracked the problem down to the engagement fork in the PTU. That is in the front end where the drive shaft attaches to the fwd transmission. It serves the function of the transfer case in an old school 4x4.

So the PTU, the RDU and one CV axle were all destroyed. My question is what triggered this catastrophic failure? I’m envisioning doing donuts for an extended period of time on snow or ice.

 

[colinl]

The RDU is the rear drive unit, ie rear differential. They say they inspected the rear axle oil and it has excess metal and they could see damaged gears through the oil drain hole. Then they replaced the rear axle. That is the RDU.

Then it was still binding up when turning, so you had them re-evaluate and with a scan tool hooked up to the car, they could see that the awd was indeed staying engaged. They then tracked the problem down to the engagement fork in the PTU. That is in the front end where the drive shaft attaches to the fwd transmission. It serves the function of the transfer case in an old school 4x4.

So then they replaced both the PTU and the RDU. That is wild.

both of them delivered underfilled on gear oil?

 

[Monkeybread72]

Thanks for breaking that down, I thought I broke the truck with water that was too deep.

 

[Phimosis]

Thanks for breaking that down, I thought I broke the truck with water that was too deep.

That is possible too. Especially if you were in the water for a long time. The RDU and PTU have vents in them to let out built up air pressure and water vapor. But this can also back flow water very slowly, a drop at a time. If you are in deep water for a long enough time, the differentials can fill up with water, which will then get emulsified with the gear oil into sludge, which then serves as a poor lubricant and poor thermal sink.

 

[Monkeybread72]

I was never in there long just a dip on a trail, I'm gonna avoid water and check it a bit more often. Thank you again for the information

 

[coco_26]

Hey everyone, I'm posting a video and some images of the error messages from my Ford Maverick 2022 FX4 2.0L EcoBoost. My truck only has less than 14,000 miles, but the other day when I started it, I heard a really loud, pulsating noise coming from what seems like the back—possibly the transmission or power transfer unit area. Shortly after, I got the all-wheel drive fault and service required alerts.

I've already taken it to the dealership and am waiting on their feedback, but I'm curious if anyone else has experienced something similar or has any insights on what might be causing this issue. Any help would be greatly appreciated!

I have this exact issue right now, did you fix it? If so I would appreciate some intel on what was the fix.

the noise on mine has changed after maybe 10 other drives.

thanks

 

[SafetyGuy]

I have this exact issue right now, did you fix it? If so I would appreciate some intel on what was the fix.

the noise on mine has changed after maybe 10 other drives.

thanks

Sorry to hear you are having problems.

Scroll up to post #18 above, I believe and have a read...it may answer your query.

Cheers

Andy

 

[coco_26]

The response #18 seemed to be a little different, the AWD starts making a noise as soon as I turn the key and once I start the car the AWD gets deactivated and I get the fault message and some others.

thanks

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