The car: Ecosport Titanuim (Keyless entry and ignition) - 1.5L (4 cylinder) Ecoboost - Automatic - 2016, '66 reg' - 22000 miles.

The problem: Car fully locked and alarmed, parked last night as normal & no problems. Then at 6:30AM this morning the car all by itself turned on the ignition, we know this because it was within range of the mobile phone and it connected to it via bluetooth. A few minutes later the car alarm went off. So we went out to turn off the alarm with the keyfob but it didn't work. Tried the button on the handle and the car unlocked. Then pressed the ignition button, which stopped the alarm but it was seen that before the button was pressed the ignition was already on. The start button was then pressed for a second time and the car turned off and all seemed normal, BUT .......

After ten minutes of peace and quiet, the car again while fully locked and alarmed, suddenly 'Started the engine' !! all by itself -  just as well the transmission was in park.

Again the car could only be opened by pressing the button on the external door handle. This time pressing the ignition button did nothing and the engine continued to keep running and could not be stopped. All instrument cluster lights that would normally be on where on, plus 'engine malfunction' light (kind of an understatement).

The only way to stop the engine was to disconnect all four injector plugs (yes, it still managed to keep running on just one cylinder).

I disconnected the battery for (20 minutes) and then reconnected - but left the injectors unplugged, just as a precaution. All seemed normal. Then pressed the ignition button, and the ignition came on as normal. Tried then to turn off the ignition and again the car just remained powered up (engine of course not running). Had to once again disconnect the battery, and have left it off.

Anyone any ideas of the fault ?

My thoughts is a fault with the BCM, but I welcome any ideas.

 

 

 

Well, I've had cars that wouldn't turn off for various reasons but never one that started on its own! Probably some faulty electronic wizardry as you suggest, but beyond me I'm afraid!

 

Have you tried Forscan?   

1 hour ago, TomsFocus said:

Have you tried Forscan?

Not yet Tom. Plan to reconnect battery later today (if it stops raining) and see how many DTC's there are.

The car has never had problems before, so this was unexpected. It did rain heavy through the night , so just wondering if that has anything to do with it.

1 minute ago, unofix said:

The car has never had problems before, so this was unexpected. It did rain heavy through the night , so just wondering if that has anything to do with it.

That's probably a fairly good bet then.  I had a similar thing happen on my old Fiesta ST...no problems at all until I washed it the day before a car meet.  Next day it wouldn't start at all, throwing all sorts of codes and numerous dash warnings.  Had to take the Focus in the end!  Tried it again the day after, started fine, would never have known there was anything wrong.  Water must have got in somewhere...no idea where, was just lucky it dried itself out!

Update:

Managed to start car last night and drive the few miles to my house. The auto transmission would only allow first or second gear, maximum speed 30 mph. The engine switched off normally and I disconnected the battery since I didn't fancy been woken up in the middle of the night by the car starting the engine !

This morning reconnect battery and tried to start the car. Ignition came on and looked normal, pressed the brake pedal and pressed start -- Nothing. repeated this a couple of times but the car does not turn over, or make any attempt to start.

Connected up FORScan and got a very long list of DTC's. I took a photo of them, and then cleared the DTC's and tried reading them again. Every one of them came back.

Disconnected the battery (again) and then set about removing the BCM for inspection (see photos). Everything looks clean, dry and in good condition. Also checked the connectors and they were also fine.

Then thought I'd inspect the ECU located on top of the battery, but after unbolting it I realised that Ford have used tamper proof 'shear off bolts' that make it impossible to get the steel mounting frame off and so it's just not possible to see or inspect the connectors.

The TCM would seem the next step but I have no idea where that is located. Any thoughts or suggestions welcomed.

 

The TCM is bolted to the front, far end, of the gearbox itself.  Not sure what access is like on the Ecosport, may just need to remove the airbox.

Did you get a 'Transmission Malfunction' dash warning at all?

2 minutes ago, TomsFocus said:

Did you get a 'Transmission Malfunction' dash warning at all?

Oh yes !!! complete with chimes and message on the centre screen

Just now, unofix said:

Oh yes !!! complete with chimes and message on the centre screen

Looks like that's the next step then!   

Very quick update:

Found the TCM (thanks for the info Tom). Looks like I can get to it from under the car. Just moved the wires to the two large connectors and the car has gone crazy !

Might possible be on to something.

News so far:

Jacked up the car and removed nearside front wheel. Then removed the inner wheel arch. Access to the two connectors was quite good. Removed both and fully inspected all the pins and checked out the sockets on the TCM. All seems to be good, no signs of water or corrosion.

Car still refuses to turn over, and instrument cluster shows engine management light and transmission malfunction light. The gear position indicator on the IC does not show that the selector is in park. I used the mechanical emergency release leaver on the selector and tried it in different positions but still nothing showing as selected on the IC.

Re-ran FORScan this time using a new profile and only a few DTC's which seemed better until I realised that anything to do with the TCM was missing. So I ran FORScan again using an older stored profile and got the message "TCM: unable to read DTC". My thoughts are that the TCM is dead or seriously not well.

Quick question, I bet Tom knows the answer.

What is this unit ?

4 minutes ago, unofix said:

Quick question, I bet Tom knows the answer.

What is this unit ?

Well I'd hate to disappoint!

It's the clutch actuator.  Will read the post above later when I've got a bit more time.

 

 

2 hours ago, unofix said:

Re-ran FORScan this time using a new profile and only a few DTC's which seemed better until I realised that anything to do with the TCM was missing

What a nightmare. If you are saying that with the new profile FORScan didn't find the TCM at all but there were lack of communication errors with everything that should communicate with it then it is likely that the TCM is shot, assuming that the fuse is ok.

I take it also if you try to read Live Data from the TCM then it does not show up.

It may have its own dedicated Can network but I don't have a wiring diagram for that car unfortunately.

45 minutes ago, Tizer said:

I take it also if you try to read Live Data from the TCM then it does not show up.

To be honest I didn't try live data but I can take a look at that on Friday.

What happened with FORScan was the vehicle had been connected to my laptop 6 months ago so I already had it's profile stored. First thing this morning I just let FORScan reload this and connected to the car. The list of DTC's was massive with about 8 or more to do with the PCM and if I remember correctly a couple were specifically listed for DTC's with TCM.

This afternoon after checking out a number of modules including the BCM and the TCM, I decided to re-run FORScan. This time I decided to not use the previous stored profile and so created a new one. The first thing I noticed was how few DTC's showed up which was a little puzzling as I'd not repaired anything. It was then I realised that in the list of modules scanned there was no TCM or any reference to it. So again I re-ran FORScan but used the old profile from 6 months ago. This time I got loads of DTC's almost all of them to do with communication problems and that the TCM could not be read. So my conclusion is that the TCM is so dead that when trying to scan with FORScan and a new profile, it simply does not find the TCM and hence it does not have any DTC's related to it.

46 minutes ago, unofix said:

So my conclusion is that the TCM is so dead that when trying to scan with FORScan and a new profile, it simply does not find the TCM and hence it does not have any DTC's related to it.

That would be my conclusion also although I would have expected a lack of communication code from the PCM to the TCM if the PCM could not find the TCM as well and it is strange that there isn't one on your last scan and I don't know why.

Incidentally the codes in your first scan relating to the PCM that end in 28 were not current codes although they may have been set when the first false start happened. The freeze frame data may have shed some light on that.

It does appear that the TCM is the cause of the current issues from your work so far.  Though if it all looks clean and dry, it seems odd that it should just completely fail like that without any warning.  I certainly wouldn't rule it out, but I am wondering if there's a 'main' cable that's been cut or chewed somewhere.  

15 minutes ago, TomsFocus said:

am wondering if there's a 'main' cable that's been cut or chewed somewhere.  

Yes that has crossed my mind. I will have a good inspection of as many cables as possible tomorrow. 

Well @TomsFocus "great minds think alike"

So today I decided to investigate the two connectors for the TCM. To gain as much access as possible I fully removed the airbox as you earlier suggested. Then from under the wheel arch I disconnected the 'Red' connector and pulled the harness and connector up in to the engine bay. Take a look at the photos to see what I found........

So only one wire was totally broken, and a further 3 had worn through the insulation (wire still good) and were shorted together. The twisted pair (Canbus I assume) had a nasty black scorch mark on them but after carefully scrapping the insulation with a knife, I was pleased to find that the insulation was still intact and that the wires had not shorted.

I set about re-insulating the 3 damaged wires and just to be on the safe side also put some insulating tape around the two canbus wires. I soldered the broken wire back together (first remembering to put the heatshrink tube on).

Now you might think that would be it, but no !!

Yes the car now starts, so that's a big plus. Reversed it off the drive and then got "Transmission Malfunction Warning". I took it for a short drive and it seems I only have the first 4 gears (better than the 2 last time I was able to drive it). Then got back home and tried to reverse it on the driveway only to find that reverse gear no longer works.

So next is to reconnect up with FORScan and see what going on.

...... and so it continues. Having left the car for an hour I returned and connected up FORScan. As expected many DTC's but after taking a photo of them (just encase), I cleared the lot and re-ran FORScan. Much to my surprise all was clear and good to go except the HVAC (not sure what it thinks is wrong but it seems to work) and also one DTC for the RFA (not even sure what that is).

Went for a short drive and for the first minute all was good. Then once again "Transmission Malfunction Warning" so turned around and headed back home.

Rescanned with FORScan and got a couple of DTC's which are very concerning. P074A:00-AF,  and also,  P2837:00-27

Also the HVAC + RFA codes.

What next ???? any thoughts @DaveT70@iantt@MasterTechTip

Do I assume that the wiring fault has caused damage to the TCM ?

Well, that's frustrating!

Difficult to know what to suggest now really.  Perhaps there was more wiring damage than immediately apparent?  (Though I know your background is in electronics!)

I wonder if it's worth trying to reset the TCM?  Though that does seem a longshot tbh.

Also seems odd that it can't select 2nd now but you had 2nd to drive over before.

HVAC fault is unlikely to be linked.  Though the RFA is something to do with key fobs I think, which might explain the initial random ignition on fault.  I'll keep thinking about it tonight...might have a brainwave at 3am lol!

The TCM has the part numbers AE8P-14085-AE and A2C30743104. The same part is used on 1.0 Fiesta, 1.0 Focus, and possibly other models as well as the 1.5 Ecosport. Is this unit programmed for the individual model/engine, and if so can it be reprogrammed using FORScan ?

That was a long read. You have been busy. What was the colour of the broken wire? 

I would do a TCM relearn if forscan lets you. The learn will engage the gears and relearn the positions. The clutch biting points will also be carried out. 

1 hour ago, iantt said:

I would do a TCM relearn if forscan lets you. The learn will engage the gears and relearn the positions. The clutch biting points will also be carried out. 

Hi Ian, thanks for reading through the tale of woe.

The broken wire was Green with Red tracer. Also damaged were a 'Blue', 'Grey', and a 'White with 'Brown' tracer.

I don't think FORScan has TCM relearn capability , but will investigate further this morning.

Gearbox is acting very odd. When the engine is first started there are no DTC's and I can engage reverse gear without a problem. Then selecting 'D' I can move off and all seems normal. At about 8mph the gearbox tries to select 2nd, but seems to go in to neutral before it skips 2nd gives a Transmission Malfunction warning and moves in to 3rd gear. From then on all seems normal except if I have to stop, in which case it pulls away in first, skips second and changes to third.

Problem when I return home is that reverse gear does not work, it is just like the gearbox is in neutral. If I switch off and try again in twenty minutes, I can select reverse ok. It would seem once the transmission malfunction warning is on you can no longer get reverse.