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Have a ‘01 AWD new front speed sensors, vss, encoder motor. Fresh fluid change following procedure. Van start up normal, no clicks. I’ll drive for 30-40 yards and then the Service AWD light pops on. Don’t have access to a tccm code reader but no ABS or DTC codes are showing.
 

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2005 Astro Cargo 4WD
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Only real way to know what’s wrong is reading the chassis codes. If you’ve got an android phone Car Gauge Pro and an ELM327 Bluetooth can read those. Other than that you’re just throwing parts at it. The TCCM uses the front and rear prop shaft speed sensor to activate the AWD. Check the pins on the TCCM connector.
 

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Reading the chassis codes is the only effective technique to identify the issue. If you have an Android phone, the ELM327 Bluetooth and Car Gauge Pro can read those. Beyond that, you are only flinging pieces at it. The front and rear prop shaft speed sensors are used by the TCCM to turn on the AWD. The TCCM connector's pins should be checked.
 

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Common Sense + Critical Thinking
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Have a ‘01 AWD new front speed sensors, vss, encoder motor.
If you are talking about the wheel speed sensors, they have nothing to do with the AWD. Mostly I use a cheap bluetooth adapter and car gauge pro, I wish they would update car gauge pro, sure needs it, but it still mostly works. I'm sure there are others out there that will read the extended codes as well.
 

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2000 Lifted 4x4 Astro 92 V8-350 Shorty
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I fixed my AWD by replacing the transfer case with a manual 233C unit.
ALL problems solved. No more issues.. works every time.

Sorry.. no help

As mentioned, the AWD system does NOT work with ABS wheels sensors.
It does work with two speed sensors (on transfer case) which monitor front vs rear drive-shaft speeds.
These are not typically a common failure point.

Normally I would suspect the encoder motor... or connection.
I've also heard they can be put in wrong.. but I'm not familiar with this.

Good luck
 
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