Copy of post made to myfordfreestyle.com. This video is for this thread.

Yesterday, our 05 AWD Freestyle came up with an AWD malfunction, and the AWD unit appeared to have shut itself off. We had this problem 2 years ago, and it was fixed by the dealer with a new AWD pump. We were able to drive it for a few days last time without an issue, the AWD just didn't kick in. This time, it is a bit more complex. Today, it popped up again and brought friends.

My wife was driving it in traffic today and when the AWD malfunction came up, the tach and temp gauges zero out. AWD malfunction shows up in the display, along with AWD data error, check traction control, check engine, check transmission. Battery and check engine idiot lights are on, as well as the traction control light and the wrench below the traction control light. I had it towed home and ran some tests. I expected to find evidence of a bad voltage regulator, battery, or loose/frayed battery connection. All checks out fine. 14.3v at idle, 14.6v at 3k rpm, 12.8v on battery with the vehicle off. Both battery cables appear to be tight and undamaged. When I drove it to try and recreate the problem, it drove for about 2 minutes on city streets and then the problem occurred again. At idle, the gauges are normal, and only awd malfunction shows in the info screen. At exactly 15mph, the tach/temp gauges drop to 0, all the other messages listed above show up, and the trans feels like it won't "shift" (adjust?) out of the lowest "gear" (bottom of the cvt pulley?). When the vehicle comes to a stop and then you start driving again, the gauges and transmission act normal until 15mph, 100% repeatable and consistent.

My code reader only goes up to 2004, and was unsuccessful in showing what codes it was throwing so I am somewhat stumped and I can't limp it to autozone to use theirs. So before I start throwing money at this problem, does anyone have any ideas where to start? This screams electrical failure (bad connection/ground) to me but I have no idea where to start on this one. I have spent a few hours doing research but this doesn't seem to fit any of the common problems. If it was a gauge cluster failure, wouldn't all of the gauges go out? It is just the 2 on ours. If it was the throttle position sensor, wouldn't it surge and/or not drive at all? Could it be a VSS issue?

Thank you for your time.

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