Ford Everest Issue: 4x4 Light And RFW Suddenly 'Engaging'

[Plugz1]

Hi Guys,

I've been more of a stalker, browsing the threads and learning from the more well informed.
I've stumbled across a problem I haven't been able to find discussed before, so:

I've got a a 2011 Ford Everest 3.0 Manual 4x4.
Vehicle is well looked after, mileage at around 250k.

Never had any issues with the vehicle, 4x4 engaging and disengaging as it should, no issues with incorrect dash lights etc etc.

Last week the vehicle was sent for a service, standard air filter, oil etc etc.
The shocks were also changed at the time.

This week, whilst driving at on the hiway, at hiway speeds the 4x4 and RFW indicators illuminated, and I hear a whirring noise.

Pull of to the side, RFW and 4x4 indicator don't want to switch off. 4x4 indicator remains illuminated in 2h, 4h and 4l, but switched off in N (between 4h and 4l).

Park the car for about 15 minutes, switch it back on, everything seems to be sorted out. RFW and 4x4 indicators are working as they should.

Drive about 1km, same issue again.


Any ideas on what could be the issue?
Do I need an autoelectrian or a mechanic?

Vehicle is parked in Durban, any recommendations and contact details for someone in the area that can diagnose and sort out the issue?

Thanks in advance for the advice gents.

[3bar]

go back to the last change on the car

they will say its not them but.......

chances are they knocked a plug off / made a bad connection when the car was on the lift

get them to put it on a lift and nosey around

dont blame them, ask them for help

[Plugz1]

go back to the last change on the car

they will say its not them but.......

chances are they knocked a plug off / made a bad connection when the car was on the lift

get them to put it on a lift and nosey around

dont blame them, ask them for help

I've already spoken to them, I apparently need an autoelectrian to diagnose the fault.
Any autoelectrian recommendations for housecalls in Durban and surrounds?

My biggest issue is, I can't drive the vehicle if the front hubs are locked. It's making a weird whirring noise that doesn't sound too healthy.

[wiel]

Crawl underneith the vehicle and look at the back side of the gearbox where the propshaft exit.
See if any wiring have shaved through on the propshaft. If there is, tape it up and position it away from the propshaft.
Now you can drive it to a workshop and have the wiring properly repaired, or do it your self.

[WernerDL]

I've already spoken to them, I apparently need an autoelectrian to diagnose the fault.
Any autoelectrian recommendations for housecalls in Durban and surrounds?

My biggest issue is, I can't drive the vehicle if the front hubs are locked. It's making a weird whirring noise that doesn't sound too healthy.

I used these guys to recently replace my battery at home. They have various other services as well.

Only used them once and the service was 4/5, so maybe use them if you don't come right anywhere else.

https://www.michanic.co.za/locations/

[Plugz1]

Following up on this...I'm trying to facilitate vehicle repairs from a distance (I've had to head up coast, work related.)

What are the potential issues?
The 4x4 indicator is coming on even with the vehicle not in 4wd. That tells me its a sensor issue.
Unless the front diff is malfunctioning. Would the 4x4 indicator light up if the front diff locks up? (do these older everests have standard locking front diffs?)
..or is the 4wd indicator linked to the front hubs locking 🤔. What's the catalyst for the indicator lighting up?

I'm confused...where are the gurus😅

[Spiceman]

There's suppose to be a sticky of the workshop manual. The workshop manual has a detailed description how the front diff setup works.
I believe the front diff is activated from the transfer case side. The hubs are automatically activated during the same sequence but deactivated by the RFW button on the dash board. The hubs are activated by vacuum. I got a mod on an Aussie forum to install a switch in the electric line that gives the signal for the activation of the vacuum. Now I can drive in 2Low. It works great in peak traffic in town.

[Plugz1]

There's suppose to be a sticky of the workshop manual. The workshop manual has a detailed description how the front diff setup works.
I believe the front diff is activated from the transfer case side. The hubs are automatically activated during the same sequence but deactivated by the RFW button on the dash board. The hubs are activated by vacuum. I got a mod on an Aussie forum to install a switch in the electric line that gives the signal for the activation of the vacuum. Now I can drive in 2Low. It works great in peak traffic in town.

Can't find a working link for that manual. If anyone has a pdf, please share.


I thought I found the problem...celebrated prematurely as well 🤦.

Found a wire under the vehicle leading from the transfer case clutch that was not securely attached and was getting chafed by the driveshaft.

Sorted out the wire, all faults and lights disappeared. Took the vehicle to gearbox centre, diff, gearbox transfer case all seem mechanically fine.
I was happy for 1 day...

Today the RFW light and issue has reappeared.

My guess is a short somewhere along that wire.
I'm not mechanically skilled, so next step is a mechanic or autoelectrician to do some troubleshooting...
Any thoughts?

[Spiceman]

Its probably that wire or another wire thats giving you grief. I'm no expert, just a poor diy'er.
I'l check later, when I get home, for the manual.

[Spiceman]

I tried to load the manual but its too big, according to the website.

Its 107MB.

[Plugz1]

I tried to load the manual but its too big, according to the website.

Its 107MB.

I think it may be the switches that connect to the solenoids. On tests, it seems that replacement switches have sorted out the issue (they were getting quite hot apparently).
I'm hoping it was the actual switch that was faulty, and not some electrical issue further down the line that caused them to go...

I would still appreciate that manual if it can find its way to me somehow. Perhaps a google drive link?

[Plugz1]

I think it may be the switches that connect to the solenoids. On tests, it seems that replacement switches have sorted out the issue (they were getting quite hot apparently).
I'm hoping it was the actual switch that was faulty, and not some electrical issue further down the line that caused them to go...

I would still appreciate that manual if it can find its way to me somehow. Perhaps a google drive link?

Hi Guys,

An update, incase someone else experiences similar issues down the line.

As I said, I'm diagnosing from a distance. My brother and a mechanic had a look at the vehicle, and informed me that the RFW switch was causing the issue (as mentioned above). These 'switches', when looking at the pictures they've sent, are actually the vacuum solenoids.
The replacement solenoids have sorted out the RFW light issue.

It seems I had a combination of issues that 'happened' to strike at the same time.

1. The wire under the vehicle that led to the transfer case was dragging against the drive shaft and got eaten through - I'm assuming that led to the 4x4 indicator lighting up.
2. The solenoid not functioning properly - that led to the RFW indicator lighting up (front hubs engaging) randomly whilst driving.

My guess is the eaten up transfer case (clutch?) wire caused a short that damaged the RFW solenoid somehow.

The solenoid serves to regulate the vacuum that drives the RFW actuator (Locking/releasing the front hubs).
Its a part common to both Mazda and Ford. Part Number: k5t49091

If anyone has further RFW complications, this thread also assisted in diagnosing my RFW issue: https://www.4x4community.co.za/forum...1296-RFW-Light


Hopefully all issues are now completely resolved.

[Spiceman]

Thats how I understand the switching also. I'm glad you got it fixed.