TSS light/PCS Malfunction See Dealer warning after lift/bumper install fix!

Hi all,

Just thought I'd share a solution to a problem I got after installing a Fox 2.5 suspension and C4 Low Pro Bumper with a winch.

Shortly after everything was installed, the TSS light went off. Took it to the dealer and they blamed the Dr. KDSS switch which is unrelated and sends error codes (on purpose) to the system. Talked to Dr. KDSS himself who was very helpful and confirmed the KDSS was doing what it was supposed to. Brought it back to the dealer with no KDSS error codes and they then blamed the bumper. Then a few days later, the PCS Malfunction See Dealer warning went on in the display and it wouldn't go away. I'd press the arrow button to clear it and it came back 5 seconds later. Talked to C4 and they said in no way is it the bumper and verified from pictures of my install that it looked good.

Felt stuck between the install place, the dealer, and the suppliers in a circular blame game.

I found a few videos and was able to solve the problem by adding two washers to the PCS sensor to re-angle it a bit more downward and that did the trick. It must have been the new suspension throwing off the geometry of the sensor. I put two washers on the two 10mm bolts on each side to angle the sensor just a bit downward. All warnings then went away!!!

Here are the videos I found helpful.

How to disconnect the PCS sensor from C4:

https://www.youtube.com/watch?v=exg6lHczt4Q&t=133s

The washer solution:

https://www.youtube.com/watch?v=4zGs21QRfG4&t=414s

Just thought this might help others in who find themselves with the same problem.

 

Excellent info.

 

Good catch!

 

I'm going to update this. The light came back on... arg!!! I tried adding a second washer to each of the side 10mm bolts and that didn't work. So I went the other way and removed the washers from the 10mm bolts and added one washer to the top screw to tilt the sensor up. That seemed to work for now! Hurray! We will see if it lasts. My next move will be to just replace the sensor ~$300. These things are finicky!

 

Look for a 3rd party in your area to recalibrate your existing sensor. Ask your local reputable body shops if they have the setup to do it. If not, who do they sublet their recalibration work to.
Seems like your sensor is working but needs recalibration. A new one will need to be calibrated as well.

 

Had the same problem when I installed the front bumper for the winch. I tried the C4 TSS sensor relocate bracket. It only worked for a short bit (a few minutes). Found out the sensor needs to be centered on the grill to work correctly. So I relocated the sensor below the original location and made a cover plate. I just cut out the bottom portion where the original sensor cover is (blank space) and made a bracket behind the grill to mount the TSS sensor. Basically dropping the sensor so it would think it is at the stock location. This mod works perfectly and had no problems since then.

 

I'm glad I left my '22 4R stock. Too many safety stuff on the new ones.

 

is yours the C4 bumper with mid height bull bar? Known to be interfering with TSS sensor no?