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Suspension & Terrain response codes
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Team Jeff
 


Member Since: 20 Feb 2009
Location: Arizona
Posts: 26

United States 2005 Discovery 3 4.4 V8 HSE Auto Chawton WhiteDiscovery 3
Suspension & Terrain response codes

Hello, I had some new codes and lights pop up today & I’m stumped! Any help would be awesome!
It’s a 2005 4.4 with 134,000 miles on it.

The codes as read by the IID tool are;

Suspension
U0416-86 (A7)

Terrain response
U0416-94 (27)
U0403-94 (27)
U0421-94 (26)

Lights on are;
Amber brake
Amber Traction control
Amber Suspension
Flashing green low range

Messages;
Transmission fault
Traction reduced
Apply handbrake
HDC fault system not available
Suspension lowered
Special programs off

Audible;
Constant beeping when handbrake is not engaged and vehicle is in park


The handbrake will set by itself each time when returning the shifter to park
The handbrake will not release when throttle is applied

I’ve tried to fix this by doing;
Replaced the brake switch
Replaced the battery
Hard reset
Clearing codes with the IID tool
Pulled the transfer case module out, opened the aluminum box and found some corrosion. Cleaned the corrosion with a fiberglass brush, reassembled using dielectric grease on connectors.

From what I’ve read on the forum the transfer case module seems like it could be the problem. Should I replace it and see what happens? I hate throwing parts at things but I’m not sure what else to try.






  
Post #19813937th Sep 2018 3:04 am
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IndusD4
 


Member Since: 01 Dec 2011
Location: Sydney, NSW
Posts: 308

Australia 2016 Discovery 4 3.0 TDV6 Base 7 Seat Auto Corris GreyDiscovery 4

I had something similar when I pulled out the wire to the transfer case on a trip in the bush. A photo of that wire is in this thread.

Ron
 2016 D4 TDV6 Corris Grey
IIDTool BT 
 
Post #19814017th Sep 2018 6:29 am
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IndusD4
 


Member Since: 01 Dec 2011
Location: Sydney, NSW
Posts: 308

Australia 2016 Discovery 4 3.0 TDV6 Base 7 Seat Auto Corris GreyDiscovery 4

The thread itself might be useful too of course.

Ron
 2016 D4 TDV6 Corris Grey
IIDTool BT 
 
Post #19814027th Sep 2018 6:32 am
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Net_fisher2
 


Member Since: 23 May 2017
Location: Isle of Wight
Posts: 99

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

That solder joint could be dry....i.e. not actually contacting the pad anymore..
All of that flux around the joint???
Have you de-soldered that chip Question

If not, get a soldering Iron on those joints and reflow those joints, may help!
Be careful, not too hot!

Just a thought!
  
Post #19814067th Sep 2018 7:19 am
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Rene_Sp
 


Member Since: 20 Sep 2017
Location: @Home
Posts: 55

Netherlands 2005 Discovery 3 4.4 V8 HSE Auto Java BlackDiscovery 3

i hope the picture is before the circuitboard was cleaned with the fiber pen.

I think the soldering of the blue resistor (could be a fuse as well) on the right of the BUK7608 is also critical

if you have a soldering iron that is not to big ,reflow that as well
  
Post #19814097th Sep 2018 7:27 am
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Team Jeff
 


Member Since: 20 Feb 2009
Location: Arizona
Posts: 26

United States 2005 Discovery 3 4.4 V8 HSE Auto Chawton WhiteDiscovery 3

I pulled the transfer case module back out today and separated the circuit board from the aluminium backing plate by drilling out the rivits. I found a little more corrosion on backside, then cleaned with a fiberglass brush and reflowed the solder in both sides where the corrosion was found. Reassembled using some small machine screws.
One note about the aluminium tabs on the box - it seems they’re only good for one “cycle” meaning the second time I opened the box the tabs all broke off. On reassembly I secured the sides of the box using aluminum tape. I was careful to leave some of the mating surface free of tape to reduce the chance of condensation.

Reassembled, no change.

Yes, that photo was before the fiberglass brush! Smile

What do you guys think? What else could I test?

I think this is probably irrelevant, but I did rebuild the compressor and repair a leaky airline recently. It’s been a few weeks and around 500mi so I think it’s unlikely there’s a connection.
  
Post #19815977th Sep 2018 9:48 pm
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Team Jeff
 


Member Since: 20 Feb 2009
Location: Arizona
Posts: 26

United States 2005 Discovery 3 4.4 V8 HSE Auto Chawton WhiteDiscovery 3

Ron, I had forgotten about this until you mentioned it - when I bought the vehicle about nine years ago, I noticed the electrical connector to the transfer case motor was cracked. I used some sealant to close it up as a preventiatve measure. I’ll have to check that out and see if there’s some corrosion.
  
Post #19815987th Sep 2018 9:55 pm
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Team Jeff
 


Member Since: 20 Feb 2009
Location: Arizona
Posts: 26

United States 2005 Discovery 3 4.4 V8 HSE Auto Chawton WhiteDiscovery 3

Just took a look at that electrical connector, couldn’t see any corrosion at all.

I did notice when I switch the key to ON I heard a light knocking sound. It only lasts for about 5 seconds but I was able to get under the vehicle fast enough to confirm it’s coming from what looks like the motor that changes the HI/LOW range in the transfer case. I don’t think I recall hearing that noise normally...can anyone confirm that?
  
Post #19816027th Sep 2018 10:27 pm
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Team Jeff
 


Member Since: 20 Feb 2009
Location: Arizona
Posts: 26

United States 2005 Discovery 3 4.4 V8 HSE Auto Chawton WhiteDiscovery 3

I removed the electric motor from the transfer case & sure enough the gear is stripped. A new carbon fiber reinforced gear is $17 on amazon and will be here in two days.

I’m hopeful this will remedy the issue!



  
Post #19816208th Sep 2018 1:52 am
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Team Jeff
 


Member Since: 20 Feb 2009
Location: Arizona
Posts: 26

United States 2005 Discovery 3 4.4 V8 HSE Auto Chawton WhiteDiscovery 3

I replaced the transfer case motor gear, recalibrated the transfer case using the IID tool & that fixed the fault codes! Thank you guys for the help!
  
Post #198299212th Sep 2018 10:33 pm
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IndusD4
 


Member Since: 01 Dec 2011
Location: Sydney, NSW
Posts: 308

Australia 2016 Discovery 4 3.0 TDV6 Base 7 Seat Auto Corris GreyDiscovery 4

Thumbs Up
 2016 D4 TDV6 Corris Grey
IIDTool BT 
 
Post #198300013th Sep 2018 12:28 am
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