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I was thinking you weren't supposed to change the rear drive unit (RDU) out without changing the module because the modules are calibrated to the RDU they were delivered with. I think if you replace the module you have to be able to pull the settings from your old module and then push them into the new unit, I believe they call it an inhale-exhale process. If your old module is not working enough to get the settings and if there's no other ways of getting the settings for that rear drive unit, from some tag on it or something that can be manually loaded to a module I think you have to replace the RDU and module as an assembly again. Again there may be some way that they can see what calibration needs to be loaded to the rear module if they do just the RDU system.

What I do know you can't just swap the rear driving without doing some calibration changes on the rear module (perhaps getting the module with the rear unit if you can't load calibrations without doing an inhale-exhale) so if that wasn't done the rear module may be very confused by the reactions it's getting from the RDU to the inputs it's giving it because it's potentially out of specs from what the loaded calibration of the module is.
 

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If Ford shipped a new RDU without the controller I would guess there was a code or something to download the calibration for it, or calibration information that should have shipped with it they can manually push into your module for it to "know" the new RDU. I can only go based on the post I've seen over the last 6 years on how the system works as I've not yet had to deal with replacing any of those parts myself. I thought I had read a while back that the controller was part of the RDU due to the "unique per RDU profile data", but with chip shortages it would make sense to get the calibration data at the factory and allow it to be loaded to the old controllers to prevent the old controllers from going to waste.
 

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This post has information, if your service center didn't load the right config into the controller for the replacement RDU there can be codes thrown, and possible damage to driveline.

 

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Did you read the pictures of the service manual that were posted in that thread?



... So if you just swap a old unit for new, connect plugs the system will not work? How the hell it's calibrated....
No, it will not work correctly if you just swap the parts. It's calibrated according to the factory service manual by using the IDS tool connected to the car to push the configuration into the all-wheel drive module. If you read that you can do it without doing the inhale-exhale from the old control module to the new module, it also states that if you are replacing the module without a control unit you must push the calibration in. The calibration can be found stamped into the RDU. I don't think it's stupid for the amount of precision they need to get into for the proper control of the vehicle. General assembly variations between clutch pack thickness or spring tension or flow rates for hydraulic system can have variations so having tested and calibrated on their systems to build a profile of that specific piece of hardware then you tell the computer what that specific piece of hardware's profile is so it knows how to control it properly to get the expected outputs.

If that is hard to read.... Blame voice to text.
 

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No, it clearly states that you can load/update the configuration data for the RDU in the AWD control module, you just need to have Ford use there IDS tool to do that.
 

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Without looking at it myself, or with enough personal experience working on them I can't say. But I can say: If the job was not done correctly, I would trying doing it correctly before replacing more parts that may not resolve the issue.
 

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You already said you did not reprogram the old control module to the calibration of the RDU you installed, so it was installed incorrectly.
 
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Well, there are electrical and module differences between the US and EU RS. I'm not sure about limitations Ford Europe may have on the dealer network service departments. But if their IDS is not licensed to support a US VIN I can see why they would not work on a non local market car.

Honestly I see no reason you would want to import a US RS over a local EU market car. EU cars had way more options and local store support. I think the only year RS that had features available in the US that was not in Europe was the 2016 with sync 3, but I think 2017 and 2018 RSs in Europe had that too.
 

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But what you can do and what a dealer is allowed to do when they are a Ford dealer or two different things. The BCMs are not the same between Europe and US. It was other differences The sensors for all the automatic headlight wipers as well you asked the 16 model had the area to support some of that but none of it was ever put in the car. We never had the city emergency braking feature. I mean the reason you could be simply that they don't want to support a car from outside the market area simply prevent people from feeling like they should be allowed to import them and use them as easily there because they make it difficult you're less likely to want to do it that may be all the reason they need I mean they're a business. Perhaps in some markets they have an issue with black market cars that were stolen in the US making it to those areas and they decided we're not going to support any US market cars in our area because odds are it might be a stolen car from the US. Again I don't know their reasoning but mean it is their business and they can pretty much choose not to work on something that's out of market area without having to give much reason other than it wasn't sold here it doesn't meet the configuration of the cars we were supposed to work on based on our training for Ford we're not doing it.

By choosing to buy an out of market car you choose to take it on yourself to do all the work automatically in my mind. If I bought an imported car from Honda that I can legally import the US now I'm not going to take it to the Honda dealer and tell them oh you have to work on this because it's a Honda. While the car may be very similar, there may be small variations unless they pay extra close attention to that they could mess up something worse on the car that they may be responsible to fix then.
 
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As I said, the configuration code from the RDU needs to be loaded into the control module for it to control that RDU to its fullest potential, and Ford warns that not loading that can cause RDU or other drive train damage. I didn't say it's hard or complicated, it's a simple concept, you just need the right tools/software to do it, and that you can't really expect a dealer to support a car from a different market.
 
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