PCS Intermittently turns off

I installed a pro grill in August and had zero issues. Fast forward to this weekend after almost two months and 3k miles with the pro grill, my PCS starts turning off randomly while driving. It’s about every other time I drive it it’ll turn off usually after anywhere from 15-40 minutes of driving. Day or night doesn’t seem to effect it. On Saturday I drove 200 miles round trip, no errors on the way up, but about halfway back that evening PCS turned off. My garnish is clean, all the connections are tight, so I am not sure what would cause it to just randomly start turning off sometimes.

Some things to note: It hasn’t rained since this started last Friday, this last weekend is when it started also happens to be the first time I’ve seen temps dipping below 50°F since owning the truck. Not sure if this is just mere coincidence but I have been using my defroster every time I’ve noticed the PCS off light. Once it turns off it will not turn back on until I turn off the truck and turn it back on. I tried searching for similar issues on the forums but it appears that these were always directly after installing the new grill and not 3k miles after. My truck is right at 12k mikes so I wouldn’t think the sensor itself is bad.

My last resort is to swap back to my stock grill, but I wanted to see if anyone here sees something I may be missing.

 

Are you absolutely sure it's random?

I have the X-Trek grill and with no spacers, it would give me the senor is dirty error whenever I was on an incline, even a slight incline. After adding washers, one at a time, I settled on 4 on the two bottom mounts. Now, it only kicks off if I'm going down a moderately steep decline.

I haven't found a good balance.

Turning the truck off and back on again turns the system back on. If you keep driving for a while, it will also turn back on.

 

It doesn’t seem to be related to inclines. Most of the times it has been on relatively flat roads. It seems like once it turns off it gets stuck on off. I drove for 30 minutes on Saturday after I got the warning and it didn’t not come back on. Additionally, if it is from something say adding more washers why would it work for 3k miles without issue? I feel like a spacing issue would have presented itself immediately.

I may go back to stock just to see if that clears up the issue, if not then I’ll take it in for warranty with the stock grill on to avoid the dealer telling me it’s not covered.

 

My only thought is that the sensor loosened over time, causing the angle to be wrong

 

Well it’s fixed (for now), albeit by swapping back to the stock grill. After work I went and checked all the bolts, all the connections and fuses just to be sure. It turned off about the time I pulled out of the parking lot. It remained off for my 35 minute commute back home. Once home I pulled the grill and sensor off, everything was clean inside and the bolts were still tight. I swapped back to the OEM grill and test drove for 30 minutes around town, even stopping by the local park to cycle through 4hi and 4lo. Made it back and everything is fine. Not sure what caused the grill to crap out after two months, but it’s not the sensor.

 

Been having the same issue on my 2021. Just had to switch the grille back to stock. Seems that the only way to add a pro grill to a 2021 or later has to be done by dealer with the trd shock upgrade.