[UPDATE 3/22/22] Dead Hybrid Maverick at 1 month old after getting "Deep Sleep Mode" messages. [Possibly fixed by software update.]

[Delzona]

Did you do that on your Maverick? You will need to bleed the air out of the system and refill with the Ford coolant. Super easy process. Luckily the coolant didn’t burn you. I know that sounds like an oxy moron.

Yeah, I did remove the hose for a second or two and shoved right back on. Yes, I was lucky it wasn't a liquid that could've burnt me.

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[Mach 1]

Deltona, I m glad I did CG when 18, I learned several careers, learn discipline, got a jump on life, worked with environments, saved millions of dollars of property, and I even saved a couple lives along the way.

You have done well as well, time Flys by so fast. I still have alot to do yet. I got to at least see whats up with this connection and will report back, I have to dodge the heat here its been over a hundred since April. I will probably do an exploratory tear down in the next couple days.

 

[Delzona]

Deltona, I m glad I did CG when 18, I learned several careers, learn discipline, got a jump on life, worked with environments, saved millions of dollars of property, and I even saved a couple lives along the way.

You have done well as well, time Flys by so fast. I still have alot to do yet. I got to at least see whats up with this connection and will report back, I have to dodge the heat here its been over a hundred since April. I will probably do an exploratory tear down in the next couple days.

Yes, I'm so glad that I joined the AF, one of the best decisions I've ever made! I to have learned so much from my time in the service, in fact I could copy and paste what you wrote about time in because it's mirrors mine, including saving lives. I went into a corner store that caught fire and got the owner, wife and child out of the building.
When I first read the possibility of this cable being the cause of "deep sleep" issue and a bad solder connection is the root cause I was also thinking if I could possibly repair the solder joint myself. I don't have any of equipment like you do so I'm going to wait for your feedback on the feasibly of doing the repair myself if necessary.

 

[Mach 1]

You know you rescued those people came from your heart, its in your blood, mine started as a job but once you get bit by it its in your blood.

I want to run out right now and tear the cables apart, but I got to have a contingency plan. I am very methodical and meticulous. I have been called anal more then once, but you got to be able to stay with this kind of repair completely and understand the defect. Only then can you have a trustworthy repair. No short cuts here.

 

[Tundra2Maverick(?)]

Day 31 - Replacement Harness arrived at Dealer and Installed. Problem apparently solved. Service Report attached.

Day 8 - Dealer Diagnosis Today (5/30/2022): Faulty Electrical Harness. The cable between the 12V battery and relay was defective. 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.

View attachment Maverick Hybrid Electric Harness Repair_6-23-2022.pdf

 

[kenswebdesign]

Day 31 - Replacement Harness arrived at Dealer and Installed. Problem apparently solved. Service Report attached.

Day 8 - Dealer Diagnosis Today (5/30/2022): Faulty Electrical Harness. The cable between the 12V battery and relay was defective. 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.

View attachment Maverick Hybrid Electric Harness Repair_6-23-2022.pdf

It seems like the problem is that ford tried to spot weld the aluminum cable to the battery terminal lugs on that cable... which is a stupid idea to begin with... so replacing the harness is the wrong answer.... all they need to do is replace the cable terminals with new crimp on lugs. There is nothing wrong with the cable per se... it is just the attachment points. As my service advisor put it, they put on a new lug and crimped the shit out of it. Problem solved.

 

[Random]

So add me to this list. Do we something to tell the dealer to look up to more quickly fix this issue?

My other post which then led me here.
https://www.mavericktruckclub.com/forum/threads/interior-lighting-when-door-opens.17877/post-340246

 

[Mach 1]

Random, have you wiggled/pulled cable yet?

 

[Tundra2Maverick(?)]

It seems like the problem is that ford tried to spot weld the aluminum cable to the battery terminal lugs on that cable... which is a stupid idea to begin with... so replacing the harness is the wrong answer.... all they need to do is replace the cable terminals with new crimp on lugs. There is nothing wrong with the cable per se... it is just the attachment points. As my service advisor put it, they put on a new lug and crimped the shit out of it. Problem solved.

It sure would help all of the Ford Dealers' Service Depts if Ford would issue a Technical Bulletin or Advisory regarding this issue. My dealer replaced the entire harness, which cost Ford a 30-day rental car, a new $700 harness, and labor.

 

[Random]

Random, have you wiggled/pulled cable yet?

Which cable? I wiggled the cables under the seat and it seemed tight. I also did under the hood connected to the positive post. It was wrapped tightly and I didn’t notice anything. The car was off for both.

My battery read at 11.83 this morning at both under the seat and the hood. While running it was over 14.

I did disconnect my Homelink mirror this morning and will keep an eye on my MPG after my commute to work.

Oh I’ll also disable vehicle diagnostics.

 

[Random]

12.3 when I got to work. All diagnostics are off and the Homelink and dash cam are unplugged. I forgot to check the MPG.

 

[Old Ranchero]

It seems like the problem is that ford tried to spot weld the aluminum cable to the battery terminal lugs on that cable... which is a stupid idea to begin with... so replacing the harness is the wrong answer.... all they need to do is replace the cable terminals with new crimp on lugs. There is nothing wrong with the cable per se... it is just the attachment points. As my service advisor put it, they put on a new lug and crimped the shit out of it. Problem solved.

that would be the vendor, not Ford, that built the cable that way. Who knows if that connection was shown on drawing/files sent to vendors that way or vendor decided to manufacture it that way? If it was manufactured per Ford specification, Quality department should have caught any bad "spot welds" on incoming inspection of 1st articles and flagged it.

 

[kenswebdesign]

It sure would help all of the Ford Dealers' Service Depts if Ford would issue a Technical Bulletin or Advisory regarding this issue. My dealer replaced the entire harness, which cost Ford a 30-day rental car, a new $700 harness, and labor.

My dealer did mention something to me that there was supposed to be a TSB on this bad cable connection problem. I have not tried to look that up to see if it is really issued, but that's what my service writer mentioned. Seems like Ford won't want to be replacing $700 cables when the problem is a 50 cent lug.

 

[Tundra2Maverick(?)]

My dealer did mention something to me that there was supposed to be a TSB on this bad cable connection problem. I have not tried to look that up to see if it is really issued, but that's what my service writer mentioned. Seems like Ford won't want to be replacing $700 cables when the problem is a 50 cent lug.

If the problem persists, I will be installing a "4-bit" lug, when it goes out of warranty.

Here is the part that my dealer replaced, (under warranty), to solve the DEAD Hybrid problem. So far, so good

 

[Random]

So I have turned off the options to send data to Ford, I’ve disconnected my Homelink, unplugged my dash cam, and have fully charged the battery. We’ll see how it looks in the morning.

Lights still don’t work when truck is off and I open my door though.

Edit: I still received the deep sleep message and I have the two options off to send data to Ford. Battery is reading 12.4 now so I truly believe there is not much else I can do. Hopefully I’m not left stranded.

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