So back in December while out driving, my 2013 Energi, despite having almost a full battery charge, abruptly started running on its engine. Both EV modes were disabled (greyed out with an "X" through them) and the only option it gave me was "EV Later". Shortly afterwards, I got a check engine light.
When I got home, I pulled the codes, and got a P2796:00 - here's what the service manual has to say about this:
P2796:00
Electric Transmission Fluid Pump Control Circuit
This DTC sets when the E-pump is not receiving a signal on it's PWM input signal from the SOBDMC / TCM .
So the Energi has an auxiliary transmission fluid pump bolted to the outside of the transmission. Because the internal transmission fluid pump is driven from the engine, the car needs a way of circulating transmission fluid when it is running in EV mode, and the engine is not running.
This pump is controlled by the SOBDMC, which is that big computer box on the driver's side in the engine bay that controls the entire electric side of the car. The SOBDMC controls the pump's speed by sending a PWM (pulse-width modulated) signal. The pump sends back a signal of some kind to the SOBDMC to let it know that it is working. If the SOBDMC doesn't see the expected "hey I'm running OK" signal from the pump, it shuts down the electric side of the house and forces the car to run on the engine only, to avoid damaging the transmission by running it without lubrication. When this occurs, it throws code P2796.
So the Ford service manual has you pull the cable from the SOBDMC end and from the pump end, and check the wires to make sure there are no opens or shorts. I did so, everything checked out fine. I cleaned all the contacts and reseated everything. I took the car out for a test drive, and within a mile or so, it threw the same code again.
According to Ford, the next "diagnostic step" is to replace the SOBDMC. Uh, yeah. Not only are those things crazy expensive, the labor to replace them is crazy (there's all kinds of coolant circuits and hoses), and they have to be programmed to the car. I'm thinking perhaps the pump is at fault. Why Ford skips that possibility in the service manual, I have no idea.
So I pulled the connector at the pump end. There are 5 wires - unswitched +12v, switched +12v (ISP-R), the PWM control signal (TAPR_CT) from the SOBDMC and the diagnostic signal (TAPR_DI) to the SOBDMC. I put my scope on the PWM control signal, and using ForScan, commanded the AUX_TLF_PMP to actuate the pump.
Here's what I saw:
So clearly I am getting PWM at the pump. All the other lines (power, ground) were fine at the pump end. The pump was NOT running when it saw this signal, so I suspected the pump was bad.
I ordered a replacement pump. I won't bore you with the story, but suffice it to say Ford doesn't have any, there were only two of them in the entire country, and it took me over two months to get it, at almost double the Ford MSRP.
Today I put the pump on, and changed the transmission fluid for good measure. I went into ForScan and commanded the pump to run. Success! I heard the pump start up, and I could control its speed by adjusting the AUX_TLF_PMP value in ForScan. When the pump was running, the AUX_TFLPMP_FB (pump feedback) was showing 48.24%:
When the pump was not running, this AUX_TFLPMP_FB number went very high, around 88%.
Just as a test, I tried plugging the harness onto the old pump and commanded it to run. It did not run, and the AUXTFLPMP_FB value stayed at around 88% (the same as when the good pump was shut off). Plugging the harness back onto the good pump, it ran as expected.
So that's it, happy ending, the pump was bad and everything is fixed, right?
Not so fast! I cleared all the codes, and as a test, with the car in the air, ran it in EV Only mode, letting the wheels rotate in the air. It ran like this just fine for about five minutes or so, but suddenly the engine started up, and the car went back to "EV Unavailable" mode, and the check engine light illuminated. I pulled the codes, and sure enough, P2796 was back again.
The strange thing is - the new pump is WORKING. I can command it. I can see in the AUX_TFLPMP_FB feedback that it can see the pump running or not.
I tried resetting codes again and repeating the test, but it's still happening.
So now I'm a bit stuck. I'm not sure what to check next. I don't know what type of signal the pump is supposed to be sending back to the SOBDMC, so I can't really check it to see if it is correct or not. The SOBDMC is seeing SOMETHING, because the value being reported for AUX_TFLPMP_FB is changing when the pump is running compared to when the pump is not.
Anyone have any suggestions? Anyone fluent with ForScan with an Energi who could try commanding their pump to run and see if the numbers being reported for AUX_TFLPMP_FB are the same as I am seeing when the pump is both operating and not operating?
I'm not entirely sure what to look at next. the P2796 code is for when the pump is "not receiving a signal on its PWM wire from the SOBDMC" - but it clearly is, because the pump is running as expected. The only way the SOBDMC would know if it is running as expected or not is through the feedback line, and it's obviously seeing SOMETHING there, because that AUX_TFLPMP_FB number is changing - but I don't know if it is changing to correct values.
Open to suggestions here. Thanks for reading this novel!
The very rare and hard to find pump installed: