Service All Wheel Drive and/or All Wheel Drive Off Message Displayed in DIC, DTC C0394 Set (Inspect Rear DIfferential Wiring Harness and Repair, If Necessary)

Some customers may comment that the Service All Wheel Drive and/or All Wheel Drive Off message is displayed in the DIC. Upon investigation, technicians may find DTC C0394 set as current or in history.

This condition may be caused by a mis-routed temperature sensor wiring harness, resulting in a wire chafe.

Follow published SI diagnostics for DTC C0394. If diagnostics lead to clutch drum replacement or are inconclusive, follow the instructions listed below before replacing any components.

1. Remove the torque tube assembly and separate the tube from the drum using the published SI procedure for driveline torque tube replacement.



2. Inspect the wiring harness for chafing (see above photo).
3. If the wire is found to be chafed, remove the drum using the published SI procedure for differential clutch drum assembly replacement.
4. Wrap the harness at least two times using 50 mm (2 in) of electrical tape.




Important: DO NOT re-use the retaining clip. Discard and use a new retaining clip.

5. Reinstall the clutch drum making sure to properly route the harness (see above photo).
6. Replace the gasket between the torque tube and rear differential using P/N 15839531 and reinstall the torque tube assembly.

For vehicles repaired under warranty, use: