AWD code 2
KISS translation of Ford gobldegook below
AWD transfer case clutch connector has failed or clutch coil has failed. no wonder a Ford tail light bulb is $5 at the stealership.
never have seen one of these clutch coils fail so suspect the connector or wiring.
the clutch connector is the 2 wire one on top of the transfer case. can post a picture of the AWD multi connector if you need it.
from Ford Service cd
2 Clutch connector or clutch coil has discontinuity.
GO to Step F1.
E4WD CLUTCH -- TEST F
² F1: BAD OR INTERMITTENT POWER TO CLUTCH
² F2: CLUTCH CIRCUIT SHORT-TO-GROUND
² F3: CONTINUITY TESTING OF CLUTCH CIRCUIT
² F4: VERIFY THE CLUTCH COIL ENGAGES
F1 BAD OR INTERMITTENT POWER TO CLUTCH
l Check the voltage at the clutch connector:
-- Disconnect the clutch harness connector from the clutch line on the transfer case housing.
-- Set the voltmeter to the 20 VDC scale.
-- Turn the ignition switch to on.
-- Shake the clutch harness and check for battery voltage between the clutch connector pin and chassis ground
F2 CLUTCH CIRCUIT SHORT-TO-GROUND
l Check for a short-to-ground on the clutch circuit:
-- Turn the ignition switch off.
-- Disconnect the module harness connector from the module.
-- Set the ohmmeter to the 20 ohm scale.
-- Shake the module harness connector and check the resistance between MHC pin 14 and chassis ground.
Resistance is intermittent or below 1 ohm
REPAIR short-to-ground on the clutch circuit. REFER to the wiring diagrams in this section.
Resistance is above 1 ohm
GO to «F3».
F3 CONTINUITY TESTING OF CLUTCH CIRCUIT
l Check for an open on the clutch circuit:
-- Turn the ignition switch off.
-- Disconnect the module harness connector from the module.
-- Set the ohmmeter to the 20 ohm scale.
-- Shake the module harness connector and check the resistance between MHC pin 14 and pin 13.
Resistance is between 1.5 and 4 ohms
GO to «F4».
Resistance is below 1.5, above 4 ohms
REPAIR open in clutch circuit or REPLACE clutch.
F4 VERIFY THE CLUTCH COIL ENGAGES
l Check the clutch by powering the circuit:
-- Disconnect the module harness connector from the module.
-- Connect Clutch Coil Locking Tool D91T-50-CLT or equivalent to the MHC. If tool is not available, ground MHC pin 13 to ground.
-- Jumper MHC pin 8 to MHC pin 14.
-- Verify clutch engagement by test driving vehicle in tight turns and noticing driveline wind-up (driveline wind-up is noticed through steering wheel feedback or wheel hop).
Clutch engages (driveline wind-up)
REPLACE the control module.
Clutch does not engage (no driveline wind-up)
REPLACE clutch or look for a mechanical failure in the system.




