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CUSTOMER CONCERN The brake pedal is hard after body repairs and DTCs C1253 and C1256 are stored. CAUSE Power-supply checks isolated the fault to the brake master-cylinder/skid-control hydraulic assembly rather than the ABS MTR No. 1 and No. 2 feeds. CORRECTION Remove and replace the failed brake master-cylinder assembly, perform the required brake-system bleed and calibration procedures, clear DTCs C1253 and C1256, and verify normal brake assist.

CUSTOMER CONCERN DTCs P0171, P0441, P0455, and P3191 set intermittently, with freeze-frame data showing high idle fuel trim like a vacuum leak. CAUSE The EVAP canister purge solenoid intermittently stuck open, creating an unmetered-vapor vacuum path that drove the lean and EVAP faults. CORRECTION Remove and replace the EVAP canister purge solenoid, clear DTCs P0171, P0441, P0455, and P3191, and verify normal idle fuel trim and EVAP-system operation.

CUSTOMER CONCERN The engine cranks but will not start and stores DTCs P3190 and P0A0F. CAUSE The in-tank fuel pump failed; multiple confirmed repairs on the same hybrid application restored starting after fuel-pump replacement. CORRECTION Remove and replace the failed fuel pump, clear DTCs P3190 and P0A0F, and verify engine starting, fuel pressure, and hybrid-system operation.

CUSTOMER CONCERN The radiator cooling fans do not operate even though both fan motors run when powered directly. CAUSE Power and ground were present at the cooling-fan ECU and the green command circuit produced the expected square-wave signal, confirming an internal cooling-fan ECU failure. CORRECTION Remove and replace the cooling-fan electronic control unit, command the fans with a scan tool, and verify normal radiator-fan operation.

CUSTOMER CONCERN Brake-booster pressure DTC P0556/00110B and pedal-travel sensor DTC 0035ED will not clear after booster and vacuum-line service. CAUSE The vacuum supply line at the electric pump was leaking and the brake-pedal travel sensor was out of adjustment after brake-booster replacement. CORRECTION Repair the leaking brake-booster vacuum supply line, adjust the brake-pedal travel sensor gap to 5 mm, clear DTCs P0556/00110B and 0035ED, and verify vacuum retention and b

CUSTOMER CONCERN The engine rattles during startup, misfires on all three bank-2 cylinders, and stores DTC P0021. CAUSE Camshaft timing was incorrect from a failed timing chain; a supporting confirmed report also documents worn guides and a camshaft actuator. CORRECTION Remove and replace the failed timing chain and related worn timing components, set camshaft timing to specification, clear DTC P0021 and the bank-2 misfire faults, and verify quiet startup and correct engine o

CUSTOMER CONCERN Fluid is leaking from the transfer-case area. CAUSE The transfer-case axle seals were leaking; Direct-Hit confirmed repair history for the same hybrid powertrain documents transfer-case seal replacement. CORRECTION Remove and replace the leaking transfer-case axle seals, refill the transfer case to specification, clean the repair area, and verify no fluid leak remains.

CUSTOMER CONCERN Cabin heat output is very low with DTCs P277300 and P277400 stored. CAUSE The PTC heater assembly had an internal open circuit; supporting checks use connector M87 terminals 6-to-7 and 8-to-9. CORRECTION Disable the high-voltage system, remove and replace the PTC heater assembly, clear DTCs P277300 and P277400, and verify normal cabin heat output.

CUSTOMER CONCERN After collision and airbag repairs, the vehicle will not enter READY mode or accept a charge, and the master and VDC warning lamps remain on. CAUSE The collision power-cutoff function remained active in the Vehicle Control Module after airbag deployment; DTC P3137 disables the system main relay until the shutdown record is cleared. CORRECTION Reset the collision power-cutoff control in the Vehicle Control Module, clear DTC P3137 and related stored faults, and

CUSTOMER CONCERN DTCs P0340 and P0344 return after an earlier camshaft-position sensor replacement. CAUSE The installed replacement camshaft-position sensor was incorrect; supporting confirmed reports also identified sensors with pre-2015 date codes covered by Ford SSM 45161. CORRECTION Remove and replace the camshaft-position sensor with the correct updated part, clear DTCs P0340 and P0344, and verify the codes do not return after drive-cycle testing.