Dead Maverick Hybrid with <2000 miles

[Powerstroke46]

On my Wednesday morning phone call with my dealship,I was told that they had to replace electrical wiring harness to resolve the Dead Maverick Hybrid Issue, but it would be probably 2weeks before they could get the harness,had a rental car that morning courtesy of the dealership,as it should be, will keep the forum updated as I get updated.

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[skyhawk]

This does not sound like an old battery or bad battery problem to me. This is a short to ground condition or some other serious parasitic load.

 

[Tundra2Maverick(?)]

On my Wednesday morning phone call with my dealship,I was told that they had to replace electrical wiring harness to resolve the Dead Maverick Hybrid Issue, but it would be probably 2weeks before they could get the harness,had a rental car that morning courtesy of the dealership,as it should be, will keep the forum updated as I get updated.

Day 8 - Dealer Diagnosis Today (5/30/2022): Faulty Electrical Harness. The cable between the 12V battery and relay was defective, (same as Powerstroke46). The replacement harness is on backorder, possibly 3-4 weeks. Thank goodness that they found the short and I do not have to live with chargers, jumpers, and uncertainty. I hope that this helps others who have, or may, experienced the problem. I had no warning signs, deep sleep messages, etc. (see below). Hybrid, built 12/22/2021.

Day 4 - Ford Service Update, Gullo Ford, Conroe, TX. Service Advisor, Dean Wachner, called today to let me know that they are perplexed and continuing to research the problem, They have opened a ticket with Ford for assistance. Battery, Alternator, and everything checks ok, but 12V battery is immediately drained when car is turned off. They are also still "working" on a loaner car.

History: Hybrid Lariat - 5 months and 4500 miles of flawless performance. No "Deep Sleep" messages or any type of warnings. May 22, I drove 10 miles, parked for 15 minutes, got back in it and it was as dead as a door nail. Never a problem of any kind before. From reading this Forum, I told myself, "Aw s!*t, Dead Maverick!". Knowing what lay ahead, and being totally pissed and extremely disappointed, I called Ford Roadside Assistance to begin the process. He jump started it with a booster, but after I turned it off, it was again completely dead. He jumped it again, and I headed straight to the Ford Dealer and parked it in the Service Lane. After driving 20 miles, it was completely dead again. May 23, I called the Ford Service Advisor, who said that the battery looked ok, and they were checking everything else for Hybrid problem possibilities.

 

[Chicora]

Day 8 - Dealer Diagnosis Today (5/30/2022): Faulty Electrical Harness. The cable between the 12V battery and relay was defective, (same as Powerstroke46). The replacement harness is on backorder, possibly 3-4 weeks. Thank goodness that they found the short and I do not have to live with chargers, jumpers, and uncertainty. I hope that this helps others who have, or may, experienced the problem. I had no warning signs, deep sleep messages, etc. (see below). Hybrid, built 12/22/2021.

Day 4 - Ford Service Update, Gullo Ford, Conroe, TX. Service Advisor, Dean Wachner, called today to let me know that they are perplexed and continuing to research the problem, They have opened a ticket with Ford for assistance. Battery, Alternator, and everything checks ok, but 12V battery is immediately drained when car is turned off. They are also still "working" on a loaner car.

History: Hybrid Lariat - 5 months and 4500 miles of flawless performance. No "Deep Sleep" messages or any type of warnings. May 22, I drove 10 miles, parked for 15 minutes, got back in it and it was as dead as a door nail. Never a problem of any kind before. From reading this Forum, I told myself, "Aw s!*t, Dead Maverick!". Knowing what lay ahead, and being totally pissed and extremely disappointed, I called Ford Roadside Assistance to begin the process. He jump started it with a booster, but after I turned it off, it was again completely dead. He jumped it again, and I headed straight to the Ford Dealer and parked it in the Service Lane. After driving 20 miles, it was completely dead again. May 23, I called the Ford Service Advisor, who said that the battery looked ok, and they were checking everything else for Hybrid problem possibilities.

Thanks for the update and letting us know. Any clue how they checked for that issue? Might save others some time.

 

[Tundra2Maverick(?)]

Thanks for the update and letting us know. Any clue how they checked for that issue? Might save others some time.

No, sorry I do not have that exact info. I can guess, but I prefer facts to opinions. They did tell me that they ran a lot of different tests during the past 8 days to find the problem. My Service Advisor did say that they contacted Ford for assistance.

If you are having the same problem and a dealer who cannot fix it, you may try to contact my advisor for advice: Gullo Ford, Conroe, TX. Service Advisor, Dean Wachner.

 

[Espeer]

If it's a relatively simple cable, rather than a complex harness, you'd think a dealership could fabricate something meeting Ford specs rather than wait a month.

 

[Tundra2Maverick(?)]

If it's a relatively simple cable, rather than a complex harness, you'd think a dealership could fabricate something meeting Ford specs rather than wait a month.

Ford Warranty arranged a loaner, so I do not mind the wait. That is one less month of wear and tear on my Maverick Hybrid! You are probably right about fixing the cable, but the dealership probably has to follow protocol on warranty repairs.

 

[huunvubu]

I have had one "Deep Sleep" message in the 5.5 months of owning my 2022 Maverick XLT Hybrid.

The 12V battery does not seem to get near or fully charged unless a lot of long trips are done. In my case my trips are relatively short and infrequent.

I have an ANCEL BST100 Battery Load Tester that I use for testing 12V batteries.

I have posted pictures showing it and the following results.

When the Deep Sleep was first reported on my FordPass App these were the results:

Deep Sleep:

Healthy: 66% 316 CCA Amps available
Charge: 29% 12.09 Volts
GOOD-RECHARGE

I then turned ON the Hybrid and it showed "ready to drive" but I just let it sit. In this mode the 12V battery should charge from the HV battery via the DC-to-DC converter. If necessary the ICE engine will run to charge the HV battery if needed. In this case it did not run.

After 30 minutes of ON time I again tested and got these results:

Healthy: 100% 412 CCA Amps available
Charge: 75% 12.55 Volts
GOOD BATTERY

A number of weeks later and after a Home Depot run that took 30 minutes each way I had these numbers:

Healthy: 100% 404 CCA Amps available
Charge: 51% 12.31 Volts
GOOD BATTERY

As can be seen the Hybrid Maverick is not doing a good job of keeping the 12V battery charged.

With this thread again mentioning "Deep Sleep" and dead 12V batteries I decided to check the state of the 12V battery in my Maverick.

It was a good thing I did because it showed this state:

Healthy: 0% NO CCA Amps available
Charge: 13% 11.93 Volts

This is basically a battery with no charge and almost dead.

So I attached my K-Mart charger (that does not overcharge) to it and it immediately started charging at 7.5 Amps. In an hour it was still putting in 2.5 Amps. At 1.5 hours the charging stopped and I again measured the battery state:

Healthy: 100% 404 CCA Amps available
Charge: 100% 12.81 Volts

I have heard that the TSB fix for the Glowing CAT also puts in software fixes that may fix this issue but have yet been able to find a dealer who will do the update without keeping my Maverick for 5-7 days while they diagnose it.

We are going on an extended 12 day road trip that will be over 2000 miles so I will be taking my K-Mart charger in case I need to recharge the 12V battery as I certainly do not want to be stranded. I also plan to measure the 12V battery status each morning to see how the state of the battery over the long trip.

The Maverick Hybrid is still not keeping the 12 Volt Battery properly charged.

In three days and many long trips the 12 Volt battery had discharged from 100% and 12.81 volts (after I had manually re-charging it) down to 36% and 12.31 volts.

@Ford Motor Company is there a fix for this problem?

I again manually re-charging it for about an hour but had to stop because I needed the truck for a trip.

I got it to 94% charge and 12.74 volts.

 

[JackZ]

I looked but couldn’t find the post about putting a bolt through the battery harness that is either loose or corroded. Mine already looks like this picture with the bolt through it. Is this a before picture and something else has to be done or is this after the fix? Just wondering if the factory started doing this before the truck was shipped.

 

[Chicora]

I looked but couldn’t find the post about putting a bolt through the battery harness that is either loose or corroded. Mine already looks like this picture with the bolt through it. Is this a before picture and something else has to be done or is this after the fix? Just wondering if the factory started doing this before the truck was shipped.

Interesting.
What was your build date?

 

[JackZ]

2/18 build date.

 

[Chris_G]

That sure looks like a NORMAL factory termination to me, what am I'm missing here??
YES! I ride the short bus so be gentle.

 

[MakinDoForNow]

Or they knew it would fail based on recent data reported to/ by Ford.

I realize that in a HYBRID, the 12v battery may have a lighter load but IMHO, 470 CCA is somewhat under powered and probably a compromise decision based on financial criteria.

Something to consider? Is the battery a glass matt like the ones that are sold for 4 wheelers and off road. In any case I suspect that there is a good possibility of a bad ground and the 14.7 +/- on the buss is not flowing through the battery sufficiently to charge it. If the battery is only seeing less than 12 v it will not charge. Am not sure but a glass mat battery depleted too low will not survive. Also some charge controllers will not even attempt to charge a 12 volt battery if it's below 7 volts (safety to prevent trying to bring 6 volt battery up to 12v. If you have a 12 v lowered than 7 you have to put the battery on a 6 v charge. Then when it is fully charged you will be able to put it on a 12 volt charger and it will not think it's a six volt battery that needs charging. Also I believe that the deep sleep is not triggered directly by the low voltage of the 12v battery but is triggered when the high voltage battery gets below a certain level and the computer has to stop trying to charge the 12v so it put vehicle into into deep sleep to prevent damaging the high voltage battery.

 

[Darnon]

I looked but couldn’t find the post about putting a bolt through the battery harness that is either loose or corroded. Mine already looks like this picture with the bolt through it. Is this a before picture and something else has to be done or is this after the fix? Just wondering if the factory started doing this before the truck was shipped.

I believe the repair mentioned would be drilling and installing a bolt to clamp where the weak solder joint would be. So approximately where the heatshrink is below the tape-wrapped convoluted tubing; the grey section of the wire near the top of the circled area.

 

[skinnyboy]

I believe the repair mentioned would be drilling and installing a bolt to clamp where the weak solder joint would be. So approximately where the heatshrink is below the tape-wrapped convoluted tubing; the grey section of the wire near the top of the circled area.

Seems like such an easy diagnosis and fix, if only temporary until a replacement cable comes in.

Can this really be the issue that has technicians and Ford scratching their heads? Not comforting.

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