Affected Vehicle(s) & Module(s)

The model(s) listed below may be affected by this issue:

Make	Model	Year	Affected Module(s)	Build Date
Ford	Explorer	2020-2021	AWD	Built on or before 30-Aug-2021
Ford	Police Interceptor Utility	2020-2021	AWD	Built on or before 30-Aug-2021
Lincoln	Aviator	2020-2021	AWD	Built on or before 30-Aug-2021

Research Report

Technical Explanation for AWD System Issues in 2020+ Ford Explorer and Lincoln Aviator

Some 2020-2021 Ford Explorer and Lincoln Aviator vehicles equipped with all-wheel drive (AWD) may experience a powertrain malfunction warning, often showing the “wrench” indicator light on the dashboard. This issue is most commonly reported in vehicles manufactured on or before August 30, 2021. Alongside the warning light, diagnostic trouble codes (DTCs) C00A6 or C0631 may appear, pointing to a fault in the front axle disconnect actuator or the associated intermediate shaft.

This document provides an in-depth guide to understanding the problem and steps to address it, aimed at owners or technicians handling these repairs.

What’s Happening?

The front axle disconnect actuator, a key component in AWD functionality, may develop wear or failure in certain models. This part allows the vehicle to disconnect or engage the front axle to optimize fuel efficiency and performance. In affected vehicles, either the actuator’s mechanical operation or its connection to the intermediate shaft can fail, leading to a malfunction signal.

What Vehicles Are Affected?

This issue specifically applies to:

• Ford Explorer (2020-2021)
• Lincoln Aviator (2020-2021)
• Models with AWD, built on or before August 30, 2021.

Symptoms

• Dashboard Warning: Illuminated “wrench” indicator.
• DTCs: C00A6 and/or C0631 stored in the vehicle’s computer system.
• Possible AWD Malfunction: Reduced drivetrain performance.

Parts Needed

To address this issue, the following parts are typically replaced. Each is essential to restoring proper functionality:

• Required Parts
  • 1 Intermediate Shaft (P/N: N1MZ-3A329-A)
  • 1 Halfshaft (P/N: N1MZ-3A427-F)
  • 1 Wheel Hub Nut (P/N: LB5Z-3B477-A)
  • 4 Engine Mount Bolts (P/N: W719326-S439)
  • 1 Engine Mount Nut (P/N: W717521-S440)
  • 2 Lower Strut-to-Wheel Knuckle Bolts (P/N: W715932-S439)
  • 2 Lower Strut-to-Wheel Knuckle Nuts (P/N: W520517-S440)
  • 2 Upper Stabilizer Bar Link Nuts (P/N: W719506-S440, varies by engine type)
  • 1 Front Axle Assembly Breather Hose (P/N: N1MZ-3B476-A)
• Optional Parts (If Needed)
  • Motorcraft® Zip Tie Strap (P/N: WA-14-SBA)
  • Motorcraft® Wire Splice Kit (P/N: 3U2Z-14A088-AB)
  • Motorcraft® Antifreeze/Coolant (P/N: VC-13-G or CVC-13-G, market-dependent)
• Lubricants
  • Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant (P/N: XY-75W140-QL or CXY-75W140-1L, as needed).

Other Solution(s):

Or, if you wish to follow the previous repair procedure, you just need to replace the following part:

• Sealing Ring (P/N: N1MZ-4A015-B). This is the part that keep failing/causing oil leaking tho!

For additional reliability, technicians might inspect related wiring and fluid levels during the repair process.

How is the Issue Fixed?

Here’s an overview of the repair process:

1. Disconnect the Battery: Safety is critical; disconnecting the battery prevents electrical accidents.
2. Remove the Faulty Actuator and Intermediate Shaft: Technicians discard these components and inspect the surrounding connections.
3. Replace Necessary Components:
   • Install a revised intermediate shaft and reassemble using new fasteners to ensure stability.
   • Replace the differential breather tube for improved reliability.
4. Update Software: Once the hardware is replaced, the vehicle’s AWD module software is updated to the latest version, and any stored DTCs are cleared.

Labor and Time Estimates

• 2-3 Hours: For models with smaller engines like the 2.3L EcoBoost.
• Up to 7-8 Hours: For larger engines, including the 3.0L EcoBoost in Aviator models.

The increased time is due to the additional components requiring removal (e.g., engine mounts or stabilizer bar links).

Why is This Important?

Ignoring this issue could lead to further drivetrain damage or inefficient AWD performance, particularly in challenging driving conditions like snow or wet surfaces. Regular maintenance and timely attention to warning lights can prevent costly repairs and ensure optimal vehicle performance.

Final Notes

If you experience this issue, visiting a qualified technician or dealership is strongly recommended. They can confirm the problem using diagnostic tools and perform the repair with the correct parts and torque specifications.

If you have any questions or need further assistance, feel free to reach out to us directly, or comment below. We will try our best to help you.