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AWD Malfunction / Haldex servicing info

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spanner555 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote spanner555 Quote  Post ReplyReply Direct Link To This Post Posted: 25 Jan 2017 at 5:26pm
I know what you mean about prices, I'm in ireland myself, and everything seems to be more expensive here too. I just quoted the sterling price as most people on this site seem to be in the uk.

If you are in any way diy inclined, the oil and filter change is not very difficult, a pit or car lift would be desirable but not essential, I managed it without. The parts can be sourced on the haldex website which is based in Holland if I remember correctly. I think €70/€80 oil,filter and delivery. I believe a volvo dealer may have them available cheaper, but they didn't have the parts here in ireland.

Not that I would encourage anything dishonest 😧😧, but if you are anxious to trade your kuga, the oil and filter change should sort your problem out until you get rid of it. Then it becomes someone else's problem after they drive it for 1000 miles.
Obviously bringing it to a dealer with an error code coming up after 20 minutes of driving is going to seriously undermine your bargaining power when it comes to trading.
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kugafinland View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote kugafinland Quote  Post ReplyReply Direct Link To This Post Posted: 17 Feb 2017 at 4:48pm
Have AWD malfunction as well, and need help from the forum.

Alarm started to go on after 1min of driving and at the same time car is going from 4WD to 2WD. Diagnosed as broken pump. I ordered new one from netherlands and local Ford service replaced the pump + haldex oils today.

However, the problem still exists. Now actually it's worse than before. 4WD is not on at all, 2WD from the start. Still I get the same AWD malfunction alarm after 1min of driving. Local service says that there are no more error codes, and I do not see them with my OBD reader either. 
What shoud be done next?

Could it be just that they haven't reprogrammed ECU after pump change? What should be the symptoms if that is the case?

Ford service would like to try to replace haldex controller as next step, which most likely is crazy expensive. No idea if that will fix the issue or not. When these control units get broken, do anyone have any ideas if they can be repaired.

I've already spend 600€ for trying to fix this AWD malfunction, and I'm not keen to spend additional +1000€.

Car is 2008 kuga with 136hpdiesel manual
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Post Options Post Options   Thanks (0) Thanks(0)   Quote kugafinland Quote  Post ReplyReply Direct Link To This Post Posted: 18 Feb 2017 at 9:47am
I'm continuing to wrap up my ideas..

1. Before the pump and oils were changed, 4WD worked as long as the engine malfunction light came on (typically about 2km). From this I would draw a conclusion that DEM and pump were at least somehow working. If either of those would be completely dead, there would not be 4WD at all. Does this sound correct?

2. After the pump and oils were changed, the car is 2WD from the start. Possible reasons:
     No power to the new pump?
     DEM somehow damaged during the service / connection problem?
     DEM needs to be reprogrammed after the pump was replaced?
     Valve/sensor issues?

3. From the service report it shows that pump and oil were replaced, but there's no mention about oil filter. This sounds quite strange to me.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tarmo120 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Feb 2017 at 8:10pm
Originally posted by kugafinland kugafinland wrote:

I'm continuing to wrap up my ideas..

1. Sounds about right

2.  I would put my money on the reprogramming of the ECU.

3. They should have changed the filter as well.


From your username I can guess that you come from Finland.
A few years back I had the excact same problem you had. (I come from Estonia, Tallinn)
And I did the excact same things you did. New pump, oil and filter. Only difference was that I changed them.
After replacing the pump the fault was still there, like nothing had changed.
The local service only wanted to sell me new Haldex of about 4000eur.
After about 4 weeks they still couldn't fix it. I had enough, so since my dad is working in Finland, I just came there for service.
The guy reprogrammed the ECU(told it to re-learn the pump parameters) and all has been fine since.
If you'd like, I can ask what was the name of the place I went.

So I think, you just have gone to the wrong service.
2008 Ford Kuga Titanium AWD Tango(Red)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote kugafinland Quote  Post ReplyReply Direct Link To This Post Posted: 19 Feb 2017 at 8:39am
Thanks a lot Tarmo for your comments!! I do live in Finland.
I would really appreciate if you could find the name of the compaly who did the reprogramming in Finland. By ECU i guess you mean this Differential Electronic Module?

Do you remember if your AWD worked at all after the pump+oil+filter change? I'm a bit worried that the Differential Electronic Module is damaged during the pump replacement because now AWD doesn't work at all, and before the pump change it always worked until the AWD alarm went on..

I'm planning to check if I can go under the car today to check if pump is running (I guess you should be able to hear that) and possibly to measure pump resistance.
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tarmo120 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tarmo120 Quote  Post ReplyReply Direct Link To This Post Posted: 20 Feb 2017 at 9:28am
In my case the pump motor was so bad that the brushes and rotor were completely worn out. And the main seal had failed so the motor was full of Haldex oil.
So before I even started to do repair and find parts, the Haldex was not working.
And while browsing the Russian forum, I found that they had same issues. And for safety I removed fuse 130(I think). So I only had front wheel drive. Also when you remove the fuse, you will lose ESP.

Yes, I believe they reset the Haldex ECU.

After replacing the oil and pump and filter the Haldex was NOT working at all. Then I took the car to the finnish service to have it ''reset'' finally.
After that, it is still working.
As a side note. If you don't have Haldex working right now, there might not be any pump activity. So don't be scared.

E: I asked the service where I went.
It is

Autokeskus Oy Konala | Helsinki |

Adress is Ristipellontie 1-7, 00390 Helsinki, Finland



Edited by tarmo120 - 20 Feb 2017 at 9:35am
2008 Ford Kuga Titanium AWD Tango(Red)
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