****REGARDING DEAD HYBRID MAVERICKS ISSUE****

[nashgas]

Not sure how to add my 2 cents on this problem but,here goes: I have 4200 miles on mine gets great gas mileage(57-60 mpg combined). Two days ago went out to start it was DEAD! Towed to dealer said found a loose battery cable connection. Told the Service Director info from here(he didn't care). Picked up yesterday,todays trip started flashing on dash electrical assist activated some functions no available(red battery symbol on dash). Turned around then flashed pull over,everything cut out while I was in traffic! Left it there walked home and had Ford Pass pick it up again. Told the Service Manager the problems found here again. We'll see what happens. P.S.-smelled electrical wire burning also.

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[Milous]

These are pictures of the cable that bolt down to the BJB from the Battery inside the cab. The cable is located between the box and the trans.

93nighthawk - The photo you posted, with the yellow arrow, is this from inside the cab near the battery, under hood, or under vehicle, I can't seem to find it...

 

[999]

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LAWSUIT!

Ford should recall every hybrid and replace the harness.. imagine if your maverick die just like that .in the tunnel, in a curve, speedway/express way/highway…. i just checked my vin and no recall not tech note whatsoever,

 

[YOBY]

It looks like there is an issue with the welds on the battery cable at the Battery Junction Box. It is hidden under the shrink tubing, so if you are having issues, I would start there.

That is a classic silver solder failure. Not enough heat or the end of the cable would be solid silver. If it happens to me, I won't go light on heat or silver solder.

 

[SLINGSHOT]

They should not be using aluminum welding type cable. Obvious effort to save money over using copper the preferred electrical conductor. As if that is not bad enough, they are soldering the cable to the connector as well as attempting to crimp as well? What the hell is that all about? Did they think they were not getting good crimps? Not using the right crimping die for the application? Ford better find a new supplier or change the specifications and procedures for such an important cable. Totally obvious these people are clueless. A first year electrical apprentice would know better. Finally, as the icing on the cake, they charge over $500 bucks for this piece of crap.

Everybody makes mistakes, but this is bush league dereliction of duty and there is no excuse for such pitiful workmanship.

After a rash of flaming mobile homes caused by mixing aluminum wires and copper joints, you would think that industry would have learned that aluminum is great for transporting 12 oz of beer. Not so good for transpoerting electrons.

 

[Scupking]

It looks like there is an issue with the welds on the battery cable at the Battery Junction Box. It is hidden under the shrink tubing, so if you are having issues, I would start there.

Send that picture to Ford...

 

[Scupking]

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Yup but of course you will have people on this Forum say it's not a big deal and not happening to a lot of people... If there are enough people just on this little Maverick club forum then imagine all the other folks that are probably having this issue...

 

[93nighthawk]

93nighthawk - The photo you posted, with the yellow arrow, is this from inside the cab near the battery, under hood, or under vehicle, I can't seem to find it...

It is under the hood.

Send that picture to Ford...

Ford is aware of the issue already.

 

[Cannedtunafishisgood]

I think that if that cable comes off it still has 12v from the battery? I am talking the cable, this seems like a fire hazard if so and should be a recall if ford is aware of issue.

 

[93nighthawk]

I think that if that cable comes off it still has 12v from the battery? I am talking the cable, this seems like a fire hazard if so and should be a recall if ford is aware of issue.

That wire is hot at all times from the 12v battery. I do not believe that it would be a fire hazard because where the lug and wire are soldered/crimped is insulated.

 

[numike]

yall scarin me! maybe I should not get a Maverick hybrid

 

[Espeer]

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Dude. AFAIK, Ford hasn't even hesitated to fix/replace these for anyone. Why lawsuit?

 

[Milous]

It is under the hood.

This one?

 

[inthecabin]

It looks to be be dipped into a solder pot without enough flux applied and/or not allowed to come up temperature for a proper eutectic bond. A vendor trying to either trying cheap out or hurrying the process to make delivery commitments.

Really no excuse and definitely a process problem. I don’t think a pull test would catch it either, maybe a peel test would.

Either way it needs to be resoldered and hopefully they’re not using antimony but probably are for green reasons.. a crimped terminal would be way better but also has a long term corrosion issue. Basically a coin flip which direction to go.

 

[93nighthawk]

This one?

Yes.

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