TSB SSM51117

[Maverick2022XL]

Nothing like hitting the lottery on a steep incline with a loaded trailer and no way to back down when the AWD system shits the bed on you. Luckily I had someone to help me get the truck onto flat ground and move the trailer. Good news is I can drive the truck otherwise in FWD mode with no traction control, collision assist, drive modes etc. until it can be dealt with. After checking the DTC codes and symptoms it matches to the tee SM51117 and my truck also happens to be a 2022. So glad Ford never did a recall on this and cost untold out of pocket expenses to their customers for a known problem that wouldn't rear it's ugly head until outside of the 3 year warranty. Thankfully I took out an extended warranty and should be covered. Something for all you 2022 owners with AWD to be aware of.

https://www.tsbsearch.com/Ford/SSM51117

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[Maverick2022XL]

The DTC codes tripped in the AWD module were C0095:71/:19

 

[n289rs]

RDU Actuator Replacement: For sub-codes C0095:71 (actuator stuck) or C0095:19 (circuit current out of range), technicians usually need to replace the rear differential actuator/RDU motor assembly rather than the entire differential. [1]

 

[Chops]

AI overview of the RDU Actuator on the AWD EB fyi…


“The RDU (Rear Drive Unit) actuator and its associated active torque coupling assembly are located underneath the rear of the vehicle directly on the rear differential housing where the rear driveshaft connects. [1, 2]





Location Details

• Position: Mounted centrally at the rear axle assembly, between the two rear half-shafts. [1]
• 
  
• Orientation: The electrical connector and actuator components sit near the front input flange of the rear differential where power enters from the rear driveshaft. [1, 2]
• 
  
• Access: You will need to lift the rear of the vehicle or use a creeper to see it clearly; dropping or temporarily removing the spare tire can provide extra working room if you are servicing nearby sensors or connectors. [1]
• 
  
• “

 

[Maverick2022XL]

AI overview of the RDU Actuator on the AWD EB fyi…


“The RDU (Rear Drive Unit) actuator and its associated active torque coupling assembly are located underneath the rear of the vehicle directly on the rear differential housing where the rear driveshaft connects. [1, 2]





Location Details

• Position: Mounted centrally at the rear axle assembly, between the two rear half-shafts. [1]
• 
  
• Orientation: The electrical connector and actuator components sit near the front input flange of the rear differential where power enters from the rear driveshaft. [1, 2]
• 
  
• Access: You will need to lift the rear of the vehicle or use a creeper to see it clearly; dropping or temporarily removing the spare tire can provide extra working room if you are servicing nearby sensors or connectors. [1]
• 
  
• “

It is also well documented in the service manual. As long as the extended warranty covers it, it is the dealer's problem, my job is to assist them in finessing the claim to get it covered if it turns out the service manager is a service monkey.

 

[Maverick2022XL]

The irony of this is my MPG has appreciably increased running in strictly FWD mode. This got me thinking why didn't they add a switch or setting in the instrument cluster to disable the AWD unless you want or need it enabled.

 

[Maverick2022XL]

So to follow up dealer wants $150 to diagnose. That may not be covered under warranty but parts and labor should be if it does turn out to be related to this TSB. So with my deductible figured in about $250 but I have to wait it out for another 3 weeks just to get it diagnosed. Debating whether to put in a new one myself since it is an easy fix and I'll be up and running in under a week. Should take 10 to 30 minutes tops to swap the motor and an oem actuator unless I can get one at MSRP is going to run $150 give or take after taxes no matter where you buy it. Reason for oem is motorcraft parts have a 2 yr warranty and if further problems arise later on with the RDU it is not an automatic warranty coverage denial because it is aftermarket.

 

[Maverick2022XL]

Final verdict, decided to replace it myself. Of course the part is out of stock and on back order from Ford but with some searching I found a dealer with one in stock. 5 days and ~$150 later the part arrived. Short story problem fixed.

Long story, it took about 2 hours to swap since I had to drop the RDU to get the actuator off. Couple of pointers since there is little information on how to change one of these. You'll need a T55 socket, 8mm socket and wrench for the job. You'll also need a breaker bar for the T55 socket and regular socket drive with a long pipe to work as a breaker if you can't get the clearance needed on the front mounting bolts. You'll need to drop the RDU to get enough clearance to remove the actuator motor. Remove the 2 T55 bolts in the front and only loosen the single T55 bolt in the back until the RDU starts to drop, If you remove it completely it you'll also need a jack of some sort to get the RDU back into place before reinstalling the mounting bolts. The lower bolt on the motor you need to do with a wrench and/or by hand, the upper bolt has enough clearance for an 8mm socket. Undoing the electrical connector is easy also once you know how it works. It has a red switch that you need to push forward to unlock the connector then you can pull it off by hand. I didn't find any torque specs for the bolts so what I did use is 80 ft/lbs for the mounting bolts and hand tight for the motor bolts.

After reinstalling I used a code reader to clear all DTC codes it threw in the AWD module and ABS module. It drove a little rough initially but I assume that was due to the AWD going through an adaptive relearn and any other modules that needed to do so. After driving it about 20 miles it was driving like it never had an issue.

So in summary if your AWD goes into fault mode and you throw those 2 specific codes you'll need to replace the RDU actuator motor part number K2GZ-4C210-A

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