23/10/23, 21:18 2020 Transit (2019)

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TECHNICAL SERVICE BULLETIN 23-2234

Engine does not start and/or various electrical faults; Water ingress into 27 July 2023

Body Control Module (BCM)

This bulletin supersedes 23-2017. Only refer to the electronic version of this TSB. Reason for update: The Service
Instruction for body sealant application in secton <Corner of cowl/dash panel joint> has been updated.

Model:
Transit Year: 2019-2023
Build Date: 01.09.2019 Onwards
Assembly Plant: Kocaeli
Transit Year: 2013-2023
Assembly Plant: Kocaeli
Transit Custom Year: 2012.75 Onwards
Assembly Plant: Kocaeli
Transit Custom Year: 2019-2023
Build Date: 01.09.2019 Onwards
Assembly Plant: Kocaeli

Markets: All European markets

Summary
Should a customer express concern about an inability to start the engine and/or various electrical faults, the probable
cause is water ingress into the Body Control Module (BCM). This would be visible by checking the BCM for water
traces/ oxidation/ corrosion at the pins. Insufficient sealing in the area of the heated windshield electrical wiring, roof
plugs and antenna hole, A-Pillar fender joint area, corner of the dash/cowl panel joint area could lead to water ingress
into the interior / BCM.
Possible various electrical faults:

• Battery management; Flat battery

• Various warning messages and indicators displayed in the instrument cluster

• Lock/unlock: not working/erratic locking feedback

• Doors: incorrect door ajar function

• Interior lighting:
- Dome lamps - erratic, not switching on/off
- IP illumination - erratic, no dimming control

• Exterior lighting - erratic, inconsistent function

• Alarm - incorrectly triggered

• Power windows - loss of function

• Wipers - No function

• Run/Start - incorrect relay function – affects modules and functions other than the BCM

• Hill launch assist malfunction

• Turn signals inoperative

NOTE: It is NOT required to install a new windshield.

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NOTE: Do NOT renew the BCM without detecting the water leak area and repairing it.
To rectify this concern, follow the attached Service Instruction.
This bulletin details the repair procedure to repair damaged wires on the BCM connector. The BCM repair connectors
(2.0L EcoBlue engine only) are available as a spare part for servicing purposes.
For vehicles built between 01.12.2022 up to 15.06.2023, please check section <Corner of cowl/dash panel joint -
Apply adhesive> first. Then follow the TSB from the beginning.
For markets where Symptom based diagnosis is used, use SBDO (In FordEtis SBDO which will be
decommissioned and replaced by PTS SBDO when available) running via the browser and select the
appropriate symptoms from the concern descriptions above. Follow the instructions to rectify this concern
and send any related diagnostic feedback session files. Failure to follow these instructions will affect any
associated warranty claim submission.
For markets where Symptom based diagnosis is not available, rectify this concern by following the attached
service repair instruction.
NOTE: Enter VIN into Microcat EPC to obtain correct parts for the vehicle.

Parts
Finis Code Quantity Description
1 937 435 1 Adhesive H-PU2 (200 ml)
2 472 359 1 Body sealant T-SMP 2 (80 ml are essential for one vehicle repair)
see Microcat EPC 1 Body Control Module (BCM) (If Required)
BCM repair connector (2.0L EcoBlue engine only) (If Required)
2 630 537 1 Repair Connector J1
2 388 043 1 Repair Connector J3
2 323 913 1 Repair Connector J4
2 388 045 1 Repair Connector J5
2 388 047 1 Repair Connector J6
2 518 482 1 Repair Connector J7
BCM repair connector (2.2L Duratorq-TDCi engine only) (If Required)
2 630 537 1 Repair Connector J1
2 388 043 1 Repair Connector J3
2 388 051 1 Repair Connector J4
2 388 045 1 Repair Connector J5
2 388 047 1 Repair Connector J6
2 388 053 1 Repair Connector J7

Labor Times
Operation
Description
No.
Diagnostic Tool - Vehicle Connection/Communication - incl. select customer symptoms, reading & 29 099 0
deleting fault codes in the relevant Ford Diagnosis and Repair System
Check for Water Entering into Interior (Water Leak Test) (Main Operation) (0.3 hours) 722750L18
Check for Water Entering into Interior (Water Leak Test) (Combination Operation) (0.1 hour) 722751L18
Body Control Module (BCM) - Removal And Install 33 626 1
Water Ingress at Heated Windshield Electrical Wiring:
A-Pillar Trim Panel - Remove And Install 43 616 1
Application of Adhesive To The Windshield (0.1 hour) 722701M19
Water Ingress at A-Pillar Fender Joint Area:

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Remove Instrument Bezel, Check for Water Entering into Interior (Water Leak Test) Apply Sealant 722753L18
(0.3 hours)
Fender - Remove And Install 41 210 0
Water Ingress at Roof Rack Plugs/Antenna:
Front Headliner - Lower 43 609 1
Application of Adhesive to Roof Rack Plugs/Antenna Socket (Combination Operation) (0.1 hour) 722701M19
Water Ingress Corner at Cowl /Dash Panel Joint Area:
Remove NVH Pad, Check for Water Entering into Interior and BCM (Water Leak Test) (Combination 722754L18
Operation) (0.1 hour)
Windshield Wiper Motor LH - Remove And Install (use only for Transit Custom LHD) 32 525 1
Windshield Wiper Motor RH - Remove And Install (use only for Transit Custom RHD) 32 526 1
Windshield Wiper Motor - Remove And Install (Transit) 32 524 1
Application of Adhesive (Combination Operation) (0.1 hour) 722755L18
New Body Control Module (BCM) - Programming 33 626 5
BCM Connector - Repair (First) (up to 31 wires) (1.4 hours) 722702M19
BCM Connector - Repair (Second) (1.2 hours) 722703M19
BCM Connector - Repair (Third) (1.2 hours) 722704M19

Repair/Claim Coding
Description Causal Part Condition Code
Windshield sealing 00357 68
A-Pillar fender joint sealing 00559 for RH
00560 for LH

General Equipment Finis Code

Spatula commercially available
Tape
Solder/shrink connectors
Tie strap
Cleaning agent
Flat nozzle (part of the clinched flange sealer (two different flat nozzles)) Locally procured or 1 136 479

Service Instruction
Check for water traces/corrosion/oxidation at the Body Control Module (BCM)

1. Check for water traces/corrosion/oxidation at the BCM.

If no water traces are found, do not proceed with further steps. For additional information, refer to Transit
Custom / Transit Workshop Manual Section 419-10.
Vehicles with 2.0L EcoBlue engine only: If corroded pins are found on the BCM connector, repair the
connector in reference to section <BCM connector - Repair>. The BCM repair connector is available as a
spare part for servicing purposes. It is NOT required to renew the complete engine wiring harness.
Warranty claims including the renewal of the complete engine wiring harness will be rejected.

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Check for water ingress at the heated windshield electrical wiring

If the vehicle is equipped with a heated windshield, the heated windshield connector area needs to be checked for
water ingress. There is no need to install a new windshield.

1. Remove the A-Pillar trim panel on the driver's side (LHD vehicle shown). For additional information, refer to
Transit Custom / Transit Workshop Manual Section 501-05.

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2. From outside the vehicle on the driver's side spread water in the area of the windshield electrical connector for
approximately five minutes. During and after this test the interior should be inspected for water ingress.
Do not use a power washer. Use a standard garden hose.
If water ingress is observed on the inside of the A-pillar, go to <Application of adhesive to the
windshield>.
If NO water ingress is observed, go to <Roof rack plug - Check>.

Application of adhesive to the windshield

1. Prepare the flat nozzle.

(1). Flat nozzle (grey)
(2). Cut for adhesive application.
(3). Using a file, sharpen the flat nozzle for better access into the gap.

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2. Using tape, to secure the surrounding sheet metal and the windshield.

3. Apply adhesive H-PU (see Parts Required) in a continuous bead inside the gap between the windshield and the
panel around the heated windshield electrical wiring.
Make sure that heated windshield connector point is covered within ± 30 mm range on A-pillar direction.
Using a spatula, to induce the adhesive into the gap.
Using suitable cleaner (General Equipment), to remove any excess adhesive.
Remove the protection tape carefully.
Allow the adhesive to dry for 30 minutes.

4. Perform the water test again to ensure that no water ingress from this area.
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5. If required, dry the floor covering of the vehicle.

Roof rack plug - Check

1. Apply water to the roof rack plugs, approximately five minutes. During and after this test the interior should be
inspected for water ingress.
(1). Roof rack plugs
Do not use a power washer. Use a standard garden hose.
If water ingress is observed on the inside of the A-pillar, go to next step.
If NO water ingress is observed, go to <Antenna hole - Check>.

2. Apply body sealant T-SMP (see Parts Required) between roof rack plugs and roof.

Antenna hole - Check

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1. Lower the front headliner. For additional information, refer to Transit Custom / Transit Workshop Manual Section
501-05.

2. Apply water to the antenna socket, approximately five minutes. During and after this test the interior should be
inspected for water ingress.
Do not use a power washer. Use a standard garden hose.
If water ingress is observed on the inside of the A-pillar, go to next step.
If NO water ingress is observed, go to <A-Pillar fender joint area - Check>.

3. Remove the antenna socket and apply body sealant T-SMP (see Parts Required) to the outer side of the seal.

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A-Pillar fender joint area - Check

1. Remove the instrument bezel on the left-hand side (LHD vehicle shown).

2. From outside the vehicle on the driver's side spread water in the area of the windshield electrical connector for
approximately five minutes.
Do not use a power washer. Use a standard garden hose.

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3. Check the area of the BCM for water ingress.

If water ingress is observed, go to next step.
If no water ingress is observed, check for other root cause for water ingress into the interior.

Front Fender - Remove and Install and apply adhesive

1. Remove the front fender on the driver's side (LHD vehicle shown). For additional information, refer to Transit
Custom / Transit Workshop Manual Section 501-02.

2. NOTE: Make sure that the A-Pillar fender joint area is properly sealed.
Apply body sealant T-SMP (see Parts Required) to the A-pillar fender joint area (LHD vehicle shown).

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3. NOTE: Adjust the fender to a minimum gap of 6 mm to the front door.

Install the front fender. For additional information, refer to Transit Custom / Transit Workshop Manual Section
501-02.

4. If required, dry the floor covering of the vehicle.

Corner of cowl/dash panel joint - Apply adhesive

1. Open the hood. Remove the NVH pad, if installed (LHD vehicle shown).

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2. Spread water 1 minute to both areas. (LHD vehicle shown).

(1). For vehicles built between 01.12.2022 and 15.06.2023 pay special attention to the body adhesive in this
area.
(2). Affected area for all build periods.

3. Check the area of the BCM for water ingress.

If water ingress is observed, go to next step and also apply <Baffle rib - Check>.
If no water ingress is observed, go to <Baffle rib - Check>.

4. Remove the windshield wiper motor (On the driver's side). For additional information, refer to Transit Custom /
Transit Workshop Manual Section 501-16.
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Torque: 10 Nm

5. Apply body sealant T-SMP (see Parts Required) to the corner of cowl / dash panel sheet metals joint area.

6. Install the windshield wiper motor in reverse order. For additional information, refer to Transit Custom / Transit
Workshop Manual Section 501-16.

7. Open the hood. Install the NVH pad, if required.

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Baffle rib - Check

1. Remove the Body Control Module (BCM). For additional information, refer to Transit Custom / Transit Workshop
Manual Section 419-10.

2. Apply water to the area shown, approximately five minutes. During and after this test the interior should be
inspected for water ingress.
Do not use a power washer. Use a standard garden hose.

3. From the inside of the vehicle, check the baffle ribs on the dash panel for water ingress.
(1). Baffle ribs on dash panel.

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(2). If water ingress is observed on the inside of the A-pillar, apply body sealant T-SMP (see Parts Required).
If NO water ingress is observed, check for other root cause for water ingress into the interior.

Body Control Module (BCM) - Renew

NOTE: The BCM design has been changed during Ecoblue engine implementation. For detailed information
refer to the relevant Workshop Manual Section on PTS.

1. Renew the Body Control Module (BCM) (see Parts Required). For additional information, refer to Transit Custom
/ Transit Workshop Manual Section 419-10.

CAUTION: Do NOT damage the electrical connectors.

Using a suitable blow-dryer or hot air gun, dry any affected connectors as necessary.
Clear any stored DTCs related to this concern.

BCM connector - Repair (2.0L EcoBlue engine only)

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1. NOTE: It is NOT required to install a new engine wiring harness.
NOTE: Arrange the solder/shrink connectors offset in groups of up to 8.
Repair the BCM repair connector (see Parts Required) in reference to TSB 16-1010.
Wires are with original color coding. For certain wires there may be a slight deviation like e.g. violet wire to
be connected to violet/grey wire. Cut and crimp wire by wire to avoid any crossed wires.

© 2023 Ford Motor Company

All rights reserved.
This bulletin represents technical service information only. Without exception all gratis repairs and replacements are subject to the individual
warranty and policy procedures of the supervisory Ford Company. The illustrations, technical information, data and descriptive text in this issue, to
the best of our knowledge, were correct at the time of publication.

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