So i drove my 2019 straight to the dealership when had loss of power bogging and dash lighting up... seen its the tube sensor thing going to clutch fa

[Jay blas]

He acted like never seen ... I'm sure he has .... I will keep posted

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[airline tech]

Thanks again yea really crazy design... I'm just stuck on how is it going to trigger all the sensors tied together when the harvest looks fine just the tube is broke View attachment 192878 View attachment 192879

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If I was working this issue, I would just replace the Fan Clutch and call it a day, but the Troubleshooter side of me would want to play with it some to see If it is an easy fix.

This is how I would tackle it and some observation notes that I know so far.

Now if the harness appears ok and it's just the hose that is broken.

1. The hose broke and allowed the module to rotate pulling on the connector, this action created a momentary bad connection. (Loss of communication) (Codes Set)

2. When the hose broke it allowed the module to rotate out of normal position, not puling harness apart. From the pics of the clutch that I have seen the module will rotate some and its rotation (allowed) is dependent on the allowed flexible movement of the hose. If you were to pull the hose off - then the module would rotate 360 degrees. (Clutch Fan - module unobstructed and not installed) (If I am CORRECT)

3. So, if the module is rotated to any position (out of its normal installed position) it will generate codes as it has lost its ability to properly read and send information and also control the fan.

4. Remember, the module is more than Power / Ground, it has the (5-Volt) VREF circuit that is communicating to other sensors and modules, if receiving an invalid signal then the other sensors and modules will fault code as well as they are losing part of their control and feedback.

Possible, easy fix for above

Replace hose, replacing hose will reposition the module to normal position.
Reset all codes generated with Scanner.

If above is (No-Help) Then dig deeper

1. The wire harness may have unseen internal wire damage (strands) or connector pin damage.
A. Perform wiring checks and repair also include (shake test) of wire harness while watching Fluke Meter.

If above is (No-Help) - Then dig deeper to the Clutch Fan itself


Now, for Internal Clutch Fan damage.

So far, without getting a Clutch Fan in my hand and playing with it and just using the previous posted video as a reference.

1. The broken hose is the key factor, what is causing the hose to break?
a. normal wear and stress imposed on it.
b. rear bearing going bad and thus putting more stress on the module / hose assembly, this being (interconnected module/ hub) not spinning freely and binding up (Grabbing Effect)
c. rear bearing grabbing might have also damaged the interconnecting knubs on the module after the hose broke and unintended rotation of the module.

The above are for a no code prior to failure possible cause.
As if the Ranger shares the basic design from the video, then the module on the back side is not physically connected to the front half of the clutch, the back side of the clutch is the control side with a bearing support.

If the Ranger would allow Bi-Directional control via Forscan or 3rd party scan tool, it would be much easier to diagnose as you can command the fan speed to note operation for testing.

So, if the hose was not broken and you just had a code and a noisy fan with noted loss of engine power then the most likely fix is a bad Fan Clutch. (Normal intended design)
As it has lost the electric control or fluid (pressure) to allow the fan to properly operate.

 

[Dr3wDrop]

Is this what we are talking about?

 

[airline tech]

Is this what we are talking about?

Yes
The hose stops the electric module from rotating completely around from the rotating force of the clutch, something is causing it to break and it puts a stress on the wire harness (pulls it apart) and or allows the harness to come into contact with the fan blades

 

[Dr3wDrop]

Yes
The hose stops the electric module from rotating completely around from the rotating force of the clutch, something is causing it to break and it puts a stress on the wire harness (pulls it apart) and or allows the harness to come into contact with the fan blades

could the hose be replaced with a metal bracket?

 

[airline tech]

could the hose be replaced with a metal bracket?

I am not 100% sure the exact design reason for the hose, only I feel that if it was designed to be solid/rigid they would have it that way.
I am thinking that it is flexible for the control aspect , control wise that fan can be sped up and slowed down (varied speed) and the flexible hose absorbs those changes (advance and decrease) of fan speed.
I may be wrong on this, but that’s how I see the reason for flexible hose.

 

[airline tech]

Think of it as running full speed clockwise and then reversing and going counter clockwise - the momentum change in between- is what it would be absorbing

 

[Racket]

Seems like the 'hose' is more a bungee cord?

Or like a rubber band being flexed to often and failing? I wonder if the ASS accelerated these failures.

 

[Colin Stuffmann]

Yes
The hose stops the electric module from rotating completely around from the rotating force of the clutch, something is causing it to break and it puts a stress on the wire harness (pulls it apart) and or allows the harness to come into contact with the fan blades

I just checked mine and it was cracked, called my service guy and in the meantime I super glued it back on.

 

[TJC]

I am going to fabricate a replacement hose, and only a couple of inches will be simply hose, an inch on each end. Just enough to secure it with the hose clamp. The majority of the hose will be re-enforced with pipe, probably copper which I can easily form to the contour of the hose. I will be replacing the original hose with something of much higher quality.

My assumption is that the hose deteriorated. Even if I am wrong, I'd rather have the clutch squeal until it freezes up, rather than have it wrap the cable around the sensor shaft shredding the cable.

And based upon the videos that I have watched, it appears that the clutches tend to weaken over time... fail mode seems to be excessive slipping.

 

[Grumpz]

I'm wondering if this is my issue. I have no way to check. Dealership replaced the number 12 fuse and "inspected" wiring finding no issues. On the way home it went out again. Low oil pressure warning followed by check engine light. Limp mode. No A/C. Now as soon as I put a fuse in, it blows. Can't even drive it. So now I'm trying to troubleshoot this in my driveway. I honestly don't see anywhere where any wires could be shorting out. Anyone know of any obvious signs? I don't see any and I'm trying to get the truck back on the road

 

[TJC]

Try unplugging the clutch fan sensor. Then add the new fuse. Then try starting the truck. You are going to need to clear the flagged errors being reported.

If it still blows the fuse look over the cable very closely to see if it has been damaged / shorted. If you are blowing the fuse you got a 12v power line shorting to ground somewhere. Could be the in clutch or wiring cable. or any other 12v device protected by that fuse.

 

[Grumpz]

Try unplugging the clutch fan sensor. Then add the new fuse. Then try starting the truck. You are going to need to clear the flagged errors being reported.

If it still blows the fuse look over the cable very closely to see if it has been damaged / shorted. If you are blowing the fuse you got a 12v power line shorting to ground somewhere. Could be the in clutch or wiring cable. or any other 12v device protected by that fuse.

That's solid advice. Didn't see any damaged wires/wiring. Truck is being towed to a different dealer with a master tech since I couldn't source any more fuses nearby. I'll report any findings and whatever wiring is shorted to help anyone in the future. From what I'm finding, this is happening a decent bit to other Rangers

 

[RedlandRanger]

That's solid advice. Didn't see any damaged wires/wiring. Truck is being towed to a different dealer with a master tech since I couldn't source any more fuses nearby. I'll report any findings and whatever wiring is shorted to help anyone in the future. From what I'm finding, this is happening a decent bit to other Rangers

Other than some isolated rodent damage I've not heard of something like this before. Certainly not a "decent bit" - at least from what I've seen/heard/read. Where are you seeing this happening a "decent bit"?

 

[airline tech]

In this instance, wiring checks and circuit breakdown (isolation) is needed along with wire harness shake test to find it.

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