TECHNICAL SERVICE BULLETIN
Illuminated Powertrain Malfunction (Wrench) Indicator With DTCs C00A6
And/Or C0631

25-2568
06 January
2026

This bulletin supersedes 25-2373. Reason for update: update the Service Procedure.
Model:
Ford
2020-2021 Explorer

AWD
Built on or before 30-Aug-2021

Lincoln
2020-2021 Aviator

AWD
Built on or before 30-Aug-2021

Markets: North American markets only
Issue: Some vehicles listed in the model statement above may exhibit an illuminated powertrain malfunction
(wrench) indicator with DTCs C00A6 and/or C0631. This may be due to the front axle disconnect
actuator/intermediate shaft.
Action: For vehicles that meet all of the criteria in the issue and model statement above, follow the Service
Procedure to replace the front axle disconnect actuator/intermediate shaft with a revised intermediate shaft.
Parts
Service Part
Claim Quantity
Number

Package
Order
Quantity

Number in
Package

LB5Z-3B477A

1

1

1

W715932S439

2

1

4

W520517S440

2

1

4

W719506S440

2 For Explorer, 3.0L
EcoBoost/EcoBoost Hybrid, 1
For All Others

1

4

W717521S440

1

1

1

W719326S439

4

1

4

N1MZ3A329-A

1

1

1

N1MZ3A427-F

1

1

1

L1MZ-4382C

1

1

1

W720050S440

1

1

4

W719503S439

1

1

4

W711310S440

1

1

4

Description
Wheel Hub Nut
Lower Strut-to-wheel Knuckle Bolt
Lower Strut-to-wheel Knuckle Nut
Upper Stabilizer Bar Link Nut
Engine Mount Nut
Engine Mount Bolt
Intermediate Shaft
Halfshaft
Engine Mount Bolt
Control Arm Nut (Aviator)
Control Arm Bolt (Aviator)
Control Arm Nut (Aviator)

W520216S440

1

1

4

N1MZ3B476-A

1

1

1

W712961S439

1

1

2

W716979S439

2

1

4

W719413S439

4

1

4

1X4Z-9E936AA

1

1

1

XY-75W140QL

As Needed

As Needed

Motorcraft® SAE 75W-140 Synthetic
Rear Axle Lubricant (All Markets
Except Canada)

CXY75W140-1L

As Needed

As Needed

Motorcraft® SAE 75W-140 Synthetic
Rear Axle Lubricant (Canada Only)

XT-12-QULV

As Needed

As Needed

Motorcraft® MERCON® ULV
Automatic Transmission Fluid

VC-13-G

As Needed

As Needed

Motorcraft® Yellow Concentrated
Antifreeze/Coolant (All Markets
Except Canada)

CVC-13-G

As Needed

As Needed

Motorcraft® Yellow Concentrated
Antifreeze/Coolant (Canada Only)

Control Arm Nut (Aviator)
Front Axle Assembly Breather Hose
Steering Shaft Bolt (3.0L)
Rear Subframe Bolt (3.0L)
Subframe Bolts Mid/Front (3.0L)
Throttle Body Gasket (3.0L)

Parts - Parts To Inspect And Replace Only If Necessary
Service Part
Number

Claim
Quantity

Package Order
Quantity

Number in
Package

WA-14-SBA

Only If
Necessary

Only If Necessary

50

3U2Z-14A088-AB

Only If
Necessary

Only If Necessary

1

L1MZ-6758-A

Only If
Necessary

Only If Necessary

1

5L7Z-7D285-A

Only If
Necessary

Only If Necessary

2

5L7Z-7J324-A

Only If
Necessary

Only If Necessary

2

W715131-S442

Only If
Necessary

Only If Necessary

4

Description
Motorcraft® Zip Tie Strap
Motorcraft® Wire Splice Kit
Tube Assembly (3.0L)
Transmission Fluid Cooler Tube
Seals (3.0L)
Fluid Cooler Tube Backing Rings
Cooler Tube Bolt (10R80 Only)

Service part numbers and "number in package" quantity may change after publication, thus also affecting the
"package order quantity". Refer to the parts catalog for the latest information.
Claim Quantity refers to the total number of individual pieces required to repair the vehicle.
Package Order Quantity refers to the amount of the service part number package(s) required to repair the vehicle.
Number In Package refers to the number of individual pieces included in a service part number package.
As Needed indicates the part is necessary but amount of the part may vary and/or is not a whole number. Parts can
be billed out as non-whole numbers, including less than 1.
Only If Necessary indicates the part is not mandatory. Refer to the Service Procedure to determine the
inspection/inclusion criteria.
Warranty Status: Eligible under provisions of New Vehicle Limited Warranty (NVLW)/Service Part Warranty
(SPW)/Service Part New Vehicle (SPNV)/Extended Service Plan (ESP) coverage. Limits/policies/prior approvals are

not altered by a TSB. NVLW/SPW/SPNV/ESP coverage limits are determined by the identified causal part and
verified using the OASIS part coverage tool.
Labor Times
Operation
No.

Description

Time

2020-2021 Explorer 4WD 2.3L EcoBoost: Retrieve DTCs And Install Intermediate Shaft
Assembly (Do Not Use With Any Other Labor Operations)

252568A

2.0
Hrs.

2020-2021 Explorer 4WD 3.3L TiVCT, 3.3L Hybrid: Retrieve DTCs And Install Intermediate
Shaft Assembly (Do Not Use With Any Other Labor Operations)

252568B

2.6
Hrs.

2020-2021 Explorer 4WD 3.0L EcoBoost: Retrieve DTCs And Install Intermediate Shaft
Assembly (Can Be Claimed With Operation E Or F And G) (Do Not Use With Any Other Labor
Operations Outside Of This Article)

252568C

7.2
Hrs.

2020-2021 Aviator AWD 3.0L EcoBoost 3.0L PHEV: Retrieve DTCs And Install Intermediate
Shaft Assembly (Can Be Claimed With Operation E Or F) (Do Not Use With Any Other Labor
Operations Outside Of This Article)

252568D

7.8
Hrs.

Additional Time To Check And Correct Caster/Camber And Front Toe (Can Be Claimed With
Operation C Or D And G)

252568E

1.1
Hrs.

Additional Time To Check And Correct Caster/Camber And Front Toe For Vehicles With Lane
Departure (Can Be Claimed With Operation C Or D And G)

252568F

1.3
Hrs.

2020-2021 Explorer 4WD 3.0L 10R80 Only: Additional Time To Remove/Install Transmission
Tubes Between The Transmission And The Cooler Bypass Valve, Includes Time Check And
Top Off Transmission fluid (Can Be Claimed With E Or F And C)

252568G

0.8
Hrs.

Repair/Claim Coding
Causal Part:

3D102

Condition Code: 42

Service Procedure
NOTE: The vehicle may have either front axle disconnect actuator with an operational electrical connector or
may have an intermediate shaft that is essentially a front axle disconnect actuator that does not have the
connection being utilized. The service replacement intermediate shaft has a different look and design but the
fit and function are the same.

2.3L / 3.0L Vehicles
1. Disconnect the battery. Refer to WSM, Section 414-01.
2. Is the vehicle equipped with a 10R80 transmission?
(1). Yes - remove the transmission cooler tubes. Refer to WSM, Section 307-02B and proceed to Step 3.
NOTE: The cooler bypass valve assembly does not need to be removed.
(2). No - proceed to Step 3.
3. Remove and discard the front halfshaft and front axle disconnect actuator. Refer to WSM, Section 205-03.
4. Is the vehicle equipped with a front axle disconnect actuator electrical connector?
(1). Yes - proceed to Step 5.
(2). No - proceed to Step 7.
5. Cut off and discard the front axle disconnect actuator electrical connector from the pigtail wiring. Make sure
enough wire is left to install the shrink tubing to properly terminate the wiring.
6. Install 1 shrink tube on 1 wire from the pigtail. Heat the shrink tube until the adhesive protrudes from both ends.
Using a pair of pliers, gently crimp both ends of the shrink tube to make sure the shrink tube is secure. Repeat the
process on the remaining 3 wires.

7. Replace the differential breather tube with the front axle assembly breather hose. Refer to 2021 WSM, Section
205-03, Removal and Installation, Differential Breather Tube.
8. Install the new service replacement intermediate shaft in place of the front axle disconnect actuator/intermediate
shaft and re-assemble. Re-use the fasteners. Refer to the 2021 WSM, Section 205-04, Removal and Installation,
Intermediate Shaft - Vehicles Built From: 31-August-2021.
(1). Tighten to 26 lb-ft (35 Nm).
9. Use the Motorcraft® Zip Tie Strap to make sure the battery cable is secured away from any rotating intermediate
shaft components.
10. Install the new halfshaft. Refer to the 2021 WSM, Section 205-04, Removal And Installation, Halfshaft - Vehicles
Built From: 31-August-2021.
11. Set the axle fluid level.
12. Vehicles equipped with 10R80 transmission only, reset the transmission fluid level. Refer to WSM, Section 30701B.
13. Update the AWD module software to the latest level and clear all DTCs.

3.3L Vehicles
1. Disconnect the battery. Refer to WSM, Section 414-01.
2. Remove both front wheels. Refer to WSM, Section 204-04A.
3. Remove and discard the front stabilizer bar link upper nut on both sides.
4. Remove and discard the left halfshaft. Refer to WSM, Section 205-04.
5. Remove the transmission cooler hose bracket nut.
6. Remove the catalyst assembly bracket, studs and nuts.
7. Place a support under the transmission bellhousing.
8. Remove the left lower engine mount nut from the subframe.
9. Using a support jack, slightly raise the engine.
10. Remove all 4 left engine mount to engine fasteners. Position the engine mount aside.
11. If equipped, disconnect the front axle disconnect actuator electrical connector and axle vent tube assembly.
12. Remove all 3 front axle disconnect actuator/intermediate shaft fasteners. Remove and discard the front axle
disconnect actuator/intermediate shaft.
(1). For vehicles with a front axle disconnect actuator, refer to 2020 WSM, Section 205-03.
(2). For vehicles with an intermediate shaft, refer to 2021 WSM, Section 205-04.
13. Is the vehicle equipped with a front axle disconnect actuator electrical connector?
(1). Yes - proceed to Step 14.
(2). No - proceed to Step 16.
14. Cut off and discard the front axle disconnect actuator electrical connector from the pigtail wiring. Make sure
enough wire is left to install the shrink tubing to properly terminate the wiring.
15. Install 1 shrink tube on 1 wire from pigtail. Heat shrink the tube until adhesive protrudes from both ends. Using a
pair of pliers, gently crimp both ends of the shrink tube to make sure the shrink tube is secure. Repeat the process
on the remaining 3 wires.
16. Replace the differential breather tube with the front axle assembly breather hose. Refer to 2021 WSM, Section
205-03, Removal and Installation, Differential Breather Tube.
17. Install the new service replacement intermediate shaft in place of the front axle disconnect actuator/intermediate
shaft and re-assemble. Re-use the fasteners. Refer to the 2021 WSM, Section 205-04, Removal and Installation,
Intermediate Shaft - Vehicles Built From: 31-August-2021.
(1). Tighten to 26 lb-ft (35 Nm).
18. Use the Motorcraft® Zip Tie Strap to make sure the battery cable is secured away from any rotating intermediate
shaft components.

19. Install the left engine mount.
(1). Tighten the new engine mount fasteners to 47 lb-ft (63 Nm).
(2). Remove the jack supporting the engine.
(3). Install the new left lower engine mount nut to the subframe. Tighten to 185 lb-ft (250 Nm).
20. Install the catalyst assembly bracket, studs and nuts. Tighten to 18 lb-ft (25 Nm).
21. Install the transmission cooler hose bracket nut. Tighten to 80 lb-in (9 Nm).
22. Install the front stabilizer bar link upper nut on both sides. Tighten to 129 lb-ft (175 Nm)
23. Install the new service replacement halfshaft. Refer to the 2021 WSM, Section 205-04, Removal And Installation,
Halfshaft - Vehicles Built From: 31-August-2021.
24. Install both front wheels. Refer to WSM, Section 204-04A.
25. Set the axle fluid level.
26. Update the AWD module software to the latest level and clear all DTCs.

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All rights reserved.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and
equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information
that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition
described affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy
and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.
The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supersede
this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.