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NHTSA ID Number: 10232494
Manufacturer Communication Number: TSB 23-2059
Summary
Some 2022 Maverick vehicles equipped with a 2.5L full hybrid electric vehicle (FHEV) powertrain may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P0402 stored in the powertrain control module (PCM). This may be due to fault detection ratio threshold of the differential pressure feedback exhaust gas recirculation (EGR) sensor. To correct the condition, follow the Service Procedure to reprogram various modules starting with the PCM and diagnose the differential pressure feedback EGR sensor.
This bulletin supersedes 22-2493.
Model:
Summary
This article supersedes TSB 22-2493 to update the Issue, Action, Service Procedure and Parts List.
Issue: Some 2022 Maverick vehicles equipped with a 2.5L full hybrid electric vehicle (FHEV) powertrain may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P0402 stored in the powertrain control module (PCM). This may be due to fault detection ratio threshold of the differential pressure feedback exhaust gas recirculation (EGR) sensor. To correct the condition, follow the Service Procedure to reprogram various modules starting with the PCM and diagnose the differential pressure feedback EGR sensor.
Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria:
Parts
Parts To Inspect And Replace Only If Necessary
| Service Part Number | Quantity | Description | Unit of Issue | Piece Quantity |
| LX6Z-9J433-A | If Needed | Differential Pressure EGR Sensor | 1 | 1 |
Quantity refers to the amount of the service part number required to repair the vehicle.
Unit of Issue refers to the number of individual pieces included in a service part number package.
Piece Quantity refers to the total number of individual pieces required to repair the vehicle.
If Needed indicates the part is not mandatory.
Service Procedure
1. Using the latest software level of the Ford
Diagnosis and Repair System (FDRS) scan tool, check the PCM for software updates. Is there a software update available for the PCM?
(1). Yes – download and run the PCM – Powertrain Control Module (PCM) Software Update app. Proceed to Step 2.
(2). No – vehicle is at the latest software level. Proceed to Step 4.
2. Check the availability for software updates on the following modules and update as required:
- Anti-lock brake system (ABS) module
- Battery energy control module (BECM)
- Secondary on-board diagnostic control module C (SOBDM-C)
3. Clear DTC P0402 from the PCM and perform a road test. Does the MIL and DTC P0402 return after performing the software updates and road test?
(1). Yes – proceed to Step 4.
(2). No – repair is complete.
4. Using FDRS scan tool monitor the differential pressure feedback EGR voltage (DPFE_V) parameter identification (PID) with the ignition on and no vacuum applied. Is the voltage between 1.90 and 2.10 volts?
(1). Yes – perform normal Workshop Manual (WSM) diagnostics outside of this article. Refer to the WSM, Section 303-08A Engine Emission Control > Diagnosis and Testing.
(2). No – replace the differential pressure feedback EGR sensor and clear DTC P0402. Refer to the WSM, Section 303-08B Engine Emission Control > Removal and Installation.
1 Affected Product
Vehicle
1 Associated Document
Manufacturer Communications
23-2059
22 February2023
MC-10232494-0001.pdf 107.944KB
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NHTSA ID Number: 10228806
Manufacturer Communication Number: TSB 22-2493
Summary
Some 2022 Maverick vehicles equipped with a 2.5L full hybrid electric vehicle (FHEV) powertrain may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P0402 stored in the powertrain control module (PCM) or brakes grab during light braking at or below 6.2 mph (10 km/h). This may be due to the software in the anti-lock brake system (ABS) module. To correct this condition, follow the Service Procedure to reprogram various modules starting with the PCM.
1 Associated Document
Manufacturer Communications
22-2493
15 December 2022
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NHTSA ID Number: 10224780
Manufacturer Communication Number: SSM 51142
Summary
Some 2022 Maverick vehicles equipped with a 2.5L full hybrid electric vehicle (FHEV) powertrain may exhibit a condition where the brakes may grab during light braking at or below 6.2 mph (10 km/h). This may be due to the software in the anti-lock brake system module (ABS). This condition does not affect vehicle safety/performance and no additional diagnosis or service is required for this condition at this time. Inform customers that they can continue to safely drive the vehicle, and engineering is currently developing a software update that is expected in the last week of November 2022. Once the software update is available, contact the customer and schedule a follow-up appointment for repair in December 2022. Monitor OASIS for updates.
1 Associated Document
Manufacturer Communications
SSM 51142
2022 Maverick – 2.5L FHEV – Brakes Grab During Light Braking When Applied At Or Below 6.2 Mph (10 Km/h)
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Reprogramming
Service Information & Reprogramming
Module Reprogramming
| Diagnostic Software | Interface Device | Complete Vehicle Diagnostics | Module Programming | ||
| 1996-2017 Model Year |
2018-Present Model Year |
1996-2017 Model Year |
2018-Present Model Year |
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| IDS/FDRS | VCM, VCM II, VCMM |
X | X | X | X |
| FJDS/FDRS | Compatible J2534 Devices (Including VCM II and VCMM) |
X | X | X | |
Detailed system requirements, installation, and support information for each product is located under the diagnostics tool support tab for each product.
Integrated Diagnostic Software (IDS) / Ford Diagnosis & Repair System (FDRS)
For use with VCM I, VCM II, VMM and VCMM hardware devices only. The complete factory Ford Motor Company vehicle diagnostic tool that provides complete dealership level vehicle diagnostic coverage for all 1996 to present Ford, Lincoln and Mercury vehicles. The IDS software includes time based access to the IDS software, software updates and calibration files.
Ford J2534 Diagnostic Software (FJDS) / Ford Diagnosis & Repair System (FDRS)
For use with compatible J2534 hardware devices. FJDS software provides Ford Module Programming functionality that covers 1996 to present Ford, Lincoln and Mercury module reprogramming functions, plus complete dealership level vehicle diagnostic software for all 2018 to present Ford and Lincoln vehicles. The FJDS software license includes time based access to the FJDS software, software updates and calibration files.
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CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool |
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CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool |
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CarDAQ-Plus |
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CarDAQ-M |
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VSI J2534 ECU Reprogrammer |
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Latest Calibration Information
Module Build Data (As-Built)
Use VIN to obtain As-Built data
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- [COMPREHENSIVE KIT] - Kit includes: VCI, WiFi adapters (wireless PC to VCI), J1962 Cable (connect to vehicle), USB cable (connect to PC for firmware updates and setup), and Quick Start Guide
SEOCONTENT-START
TECHNICAL SERVICE BULLETIN 2.5L FHEV – Illuminated MIL With DTC P0402 23-2059 22 February2023 This bulletin supersedes 22-2493. Model: Ford 2022 Maverick Engine: 2.5L FHEV Summary This article supersedes TSB 22-2493 to update the Issue, Action, Service Procedure and Parts List. Issue: Some 2022 Maverick vehicles equipped with a 2.5L full hybrid electric vehicle (FHEV) powertrain may exhibitan illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P0402 stored in the powertraincontrol module (PCM). This may be due to fault detection ratio threshold of the differential pressure feedbackexhaust gas recirculation (EGR) sensor. To correct the condition, follow the Service Procedure to reprogram variousmodules starting with the PCM and diagnose the differential pressure feedback EGR sensor. Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria: • 2022 Maverick • 2.5L FHEV • Illuminated MIL with DTC P0402 stored in the PCM Parts Parts To Insepct And Replace Only If Necessary Service Part Number Quantity Description Unit of Issue Piece Quantity LX6Z-9J433-A If Needed Differential Pressure EGR Sensor 1 1 Quantity refers to the amount of the service part number required to repair the vehicle. Unit of Issue refers to the number of individual pieces included in a service part number package. Piece Quantity refers to the total number of individual pieces required to repair the vehicle. If Needed indicates the part is not mandatory. Warranty Status: Eligible under provisions of New Vehicle Limited Warranty (NVLW)/Emissions Warranty/ServicePart Warranty (SPW)/Special Service Part (SSP)/Extended Service Plan (ESP) coverage. Limits/policies/priorapprovals are not altered by a TSB. NVLW/Emissions Warranty/SPW/SSP/ESP coverage limits are determined bythe identified causal part and verified using the OASIS part coverage tool. Labor Times Description OperationNo. Time 2022 Maverick 2.5L FHEV: Reprogram The Appropriate Modules As Required By TheSoftware Update And Service Procedure, Includes Time To Check And Clear DTCs, RoadTest And Replace The Differential Pressure Feedback EGR Sensor If Required (Do Not UseWith Any Other Labor Operations) MT232059 ActualTime Repair/Claim Coding Causal Part: 9J433 Condition Code: 42 Service Procedure 1. Using the latest software level of the Ford Diagnosis and Repair System (FDRS) scan tool, check the PCM forsoftware updates. Is there a software update available for the PCM? (1). Yes – download and run the PCM – Powertrain Control Module (PCM) Software Update app. Proceed to Step2. (2). No – vehicle is at the latest software level. Proceed to Step 4. 2. Check the availability for software updates on the following modules and update as required: Anti-lock brake system (ABS) module Battery energy control module (BECM) Secondary on-board diagnostic control module C (SOBDM-C) 3. Clear DTC P0402 from the PCM and perform a road test. Does the MIL and DTC P0402 return after performingthe software updates and road test? (1). Yes – proceed to Step 4. (2). No – repair is complete. 4. Using FDRS scan tool monitor the differential pressure feedback EGR voltage (DPFE_V) parameter identification(PID) with the ignition on and no vacuum applied. Is the voltage between 1.90 and 2.10 volts? (1). Yes – perform normal Workshop Manual (WSM) diagnostics outside of this article. Refer to the WSM, Section303-08A Engine Emission Control > Diagnosis and Testing. (2). No – replace the differential pressure feedback EGR sensor and clear DTC P0402. Refer to the WSM, Section303-08B Engine Emission Control > Removal and Installation. © 2023 Ford Motor Company All rights reserved. NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, andequipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides informationthat could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a conditiondescribed affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policyand 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 supersedethis information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.
SEOCONTENT-END
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