Warn Hidden Winch Mount trigger PCS and TSS malfunction

Hey There,

I've got a 2020 TRD-OFF Road Premium, and I recently got warn's 12-ton winch and Rago Fabrication hidden winch mount installed under my front grille. The mount and winch say it's compatible with the sensor, but after the installation, the warning light came on. At first, it was just the yellow PCS light that came on, but now the entire sensor says it's malfunctioned and gets a huge text on the dash to "visit the dealer." I took it to my local dealer, they spent 3 days trying to fix it, but couldn't figure it out. They blamed it on my front grill sensor needing to be replaced, but even after that 300-dollar part replacement, they couldn't promise that the light would come off. They blame the lack of OEM grill parts on the car, but all the 3rd party mods I have say they're compatible with the sensor &PCS/TSS technology. The sensor was working fine right before the winch install... I can't figure out what the issue is, but everyone is telling me I need to choose whether to disable the sensor or keep the winch installed. I find this hard to believe because Warn says it's compatible... Any ideas?

 

Did you happen to start the car in the middle of the install while things were unplugged? I heard that has caused problems.

Also, it’s easy to pinch/damage the radar bracket/wires during install. I almost did that myself. Have you gotten a chance to take things apart and inspect yourself? I can see dealers doing a quick visual inspection and recommending new parts before really making sure they’ll solve the problem.

 

One more thing even though I doubt it’s the problem. Remove that license plate bracket to see if the code goes away. You never know…

 

I'm running into a similar issue with TSS acting up with raptor lights.

I'll let you know if I find anything.

 

You have probably already confirmed that the TSS sensor plug was fully seated when reconnected but if you haven’t, that’s the first item. Followed by a close inspection of the TSS wiring harness to make sure it wasn’t damaged during install.
I installed my SSO Slimline bumper and winch in my garage and remember disconnecting the TSS harness to remove the grill and grimaced hoping it would work once reconnected. It worked just fine and I suspect that you either have a loose or damaged connector or damaged wiring. Remove the plastic panel above and inspect. I wouldn’t trust that the dealer tech did this without checking.

If you’ve already done this, then ignore my comments….

Cheers,
Bob

 

Maybe the problem is that 12-Ton winch...sounds like something that belongs on a front end loader...

 

1. It looks like you might be gettign false readings as that plate sits to high, it may be deflecting off of it causing the reading issue.

2. Just say not to #nannytech

 

Thank you all for the guidance. To answer some of the questions, the car was off when the cable was disconnected. I double checked the connection of the cable, and they all fit snug. To my knowledge, there were no issues with the cable being cut or damaged during the install. However, there is a bandage on a portion of the wire (see photo attached) but was told thats from the factory…


I haven’t had any problems with the sensor up until the winch install so the raptor lights and grille have not affected it. I also have an eibach lift, but none of which had tampered with the sensor’s functionality. I ensured that nothing was blocking the sensor and the corresponding camera on the windshield.

I’ll attach photos below of the inside of the grille.

 

I have a 2021, 4runner that had zero issues with the TSS sensor before i added a lift kit to my vehicle. About a month after installing the kit, I started having the same issues that you're describing. At first, it was just the yellow sensor light that was on and then after that I'd get the message on my dash telling me to visit the dealer. It was intermittent though. All of the warning lights would disappear after a couple weeks and then the whole thing would start over again. First it was the yellow dash light, and then the warning message on the dash. Eventually, the message just never went away and every time I drove my vehicle, that message was on the dash. It drove me nuts.

I asked the dealership about it when I took my car in for an oil change but they said that it would cost me a $375 diagnostic fee and they couldn't guarantee that the issue could be fixed. I declined and decided to just live with the issue.

A few months after that I was browsing this forum and came across this TSS relocation kit from C4 Fabrications. I installed the relocation bracket and turned the vehicle on.. error message still hadn't gone away. I felt a little discouraged but I decided to take the vehicle for a short test drive. I drove for about 5 minutes and turned the vehicle off and then on again. Error message disappeared and hasn't been back in 4 months. It's a lot of money for a piece of metal but it brought such peace of mind and it was 100% worth it for me to have my cruise control back. Hopefully this helps you.

https://c4fabrication.com/products/4runner-tss-relocation-kit

 

I relocated the TSS sensor down after installing the bumper. Haven't had any issues. I had to do a bit of modification to the the grill and make a cover to protect it.

 

I ordered this bracket and installed it last week. Problem resolved, thank you. I highly recommend this bracket for anyone else who is encountering a similar problem. I was worried my raptor lights and TRD Pro replica grille would affect the mounting, but as long as the sensor has a clear view without metal obstruction, there shouldn’t be any issues. I believe the original OEM sensor location was obstructed by thick metal winch. This C4 bracket moves the sensor higher up, above obstructions. The install is easy if you follow the C4 youtube video.

 

Glad you got it sorted, I'm kinda surprised you had issues in the first place. I have a hidden winch, looks just like your set-up basically and have had no issues with my TSS.

Since you're good now, would you mind sharing the license plate bracket adapter you've got mounted there? I see it lowers the plate and adds a flippy. I've been trying to find a plate solution that I like and haven't yet.

 

This is awesome info to know. Many of us freak out that the slightest relocation of where the sensor “expects” to be will throw off calibration and codes. Including a lot of people worrying that a lifting the vehicle by itself would cause the problem (at least when these sensors were first introduced). When you look at the costs lf calibrating the system, it’s easy to understand the worry.

However, with the relocation bracket, it’s possible the sensors wont trip a code/warning light but not function as intended because of their new position. If you see any weird behavior (during use of radar cruise, or inappropriate emergency TSS braking) please report back and share your experience.

Knowing this works to get rid of the warning lights opens up all sorts of bumper options. For example, if I knew this back when I got my warn winch mount bumper, I would have gotten the version with a hoop and used the bracket. I could care less about the radar cruise function. But I wouldnt be able to stand seeing a warning light all the time. Great option to have!!!

 

I've had my grill and bumper cover off twice, once to install an SSO slimline bumper, and again to install my winch. The second time I was worried that I had stressed or cracked the TSS connector, so I pushed it together tightly and dripped a bit of hot glue on the plug as insurance[holds well and easy enough to remove]
Thankfully it is working just fine.
Just passing on a tip, good luck with your issue.

 

Not having the TSS function properly is a legitimate concern. I've had this installed for almost 6 months now and all functions of TSS are functioning as they should.

 

Thanks for posting your experience!

 

Im having the same issues. Sensor has been relocated but still says See your dealer. took it to them but they woould not do anything unless it's put back to its original state which is getting rid of the Westin bumper that I installed. sucks. don't care about the PCS but since the cruise control is not working at all, it really is disppointing.

 

Hold the cruise control button for 3 seconds to disable the TSS sensor. Cruise control will work as a regular function. This option is mentioned in the manual.

 

Thanks. Tried it but it now says Cruise Control Malfunction, See your Dealer.

 

It will definitely say that when trying to use the adaptive cruise control. Are you sure you've switched over to the basic, non-adaptive, old-fashioned cruise control?

 

Check out this thread if you have the "permanent" PCS fault, and your sensor is not obstructed: https://www.4runners.com/threads/er...s-after-lift-and-alignment.35631/#post-528005

 

Is this a full bumper or middle section bumper? I got the hidden winch bumper and had to lower the TSS sensor to get it to work. If it is not in the middle lower section (TSS sensor), it would have to be recalibrated by Toyota. Also, what year is your 4runner? I heard that 2020 model had issues with the TSS sensor since this was the first year is was added to the 4runner. The part number for the TSS sensor is 88210-35020. New sensor still has to be calibrated. Hope this helps.

 

it's a 2023 ORP. I'm surprised Toyota didn't mention it to me that I can disable it in order for cruise control to work when it took it there to calibrate. I paid 500+ for it but it didn't work. I was told that they would only fix it if the original bumper is installed back. I have the low profile Westin bumper and it's partially covering the rectangular plastic sensor. It worked for the first 2 months, then it started failing intermittently and completely died since Oct last year.

 

BTW, I took it the shop that installed the Westin bumper. They recommended to move the sensor somewhere but it still didn't work. I already spend over 1k just to get this fixed.

 

is that an available option for 2023 ORP? Thanks.

 

Yes, the 2023 ORP has both kinds. The adaptive mode they call "vehicle-to-vehicle distance control mode", and the old-fashioned kind they call "constant speed control mode". The 2023 ORP manual describes the two modes in pp 257-269. The way to get constant speed mode is on p 266: with cruise control off, press and hold the "on/off" button on the cruise control stalk for at least 1.5 seconds.

 

Thanks man! I was able to make it work yesterday. I can use cruise control again.