Tracking DEAD HYBRID Mavericks Reported Dealer Solutions / Fixes ...

[skinnyboy]

It appears that the faulty cable connections are a time bomb on every Hybrid. It is just a matter of time before they break and go dead. My cable was replaced by my dealer over a month ago, and my fingers are still crossed.

I think you hit the nail on the head. Previously it seemed that it would have been a bad batch of cables and fairly easy to contain on Ford's end. After reading of a few regular posters' "Mine died today too." stories it seems like a bigger issue.

Cheers.

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[Jcaudi]

A couple of weeks ago I first experienced the issue of my hybrid maverick going completely dead when turning the truck off. I was able to wiggle the cable and eventually got it to power back on.

I immediately contacted my local dealership and scheduled the next available appointment (2weeks out). The issue would continue to occur every couple days, but I was always able to get it back on. I finally got into the dealership, made them aware of the issue and what I've read here on the forum (mentioning replacing the wiring harness, which they didn't listen to). They have my truck for a couple days and the service tech said he was aware of the issue and that the solution was to sodder the wire, because they come crimped from the factory and it can wiggle loose. I was happy to have my truck back and to have this issue behind me... for 5 days.

This morning my truck was dead again. Per usual I wiggled the wire, but it took longer to come back on than it typically did. Was able to carefully drive to work this morning, where it died again. So obviously, not fixed, I've contacted the dealership again and I'm waiting to hear back.

Is the current thinking that just replacing the wiring harness resolves the issue?

 

[skinnyboy]

A couple of weeks ago I first experienced the issue of my hybrid maverick going completely dead when turning the truck off. I was able to wiggle the cable and eventually got it to power back on.

I immediately contacted my local dealership and scheduled the next available appointment (2weeks out). The issue would continue to occur every couple days, but I was always able to get it back on. I finally got into the dealership, made them aware of the issue and what I've read here on the forum (mentioning replacing the wiring harness, which they didn't listen to). They have my truck for a couple days and the service tech said he was aware of the issue and that the solution was to sodder the wire, because they come crimped from the factory and it can wiggle loose. I was happy to have my truck back and to have this issue behind me... for 5 days.

This morning my truck was dead again. Per usual I wiggled the wire, but it took longer to come back on than it typically did. Was able to carefully drive to work this morning, where it died again. So obviously, not fixed, I've contacted the dealership again and I'm waiting to hear back.

Is the current thinking that just replacing the wiring harness resolves the issue?

I'd be curious to see what the dealership did to solder the termination on the cable. As some have posted their dealers that did a repair used a crimp fitting.

Which termination came loose on yours, the one easily visible behind the black plastic cover that tips forward, or the cable behind it?

Assuming Ford has the cable supplier providing good cables at this point a replacement should be a permanent fix.

Cheers.

 

[Chris_G]

A couple of weeks ago I first experienced the issue of my hybrid maverick going completely dead when turning the truck off. I was able to wiggle the cable and eventually got it to power back on.

I immediately contacted my local dealership and scheduled the next available appointment (2weeks out). The issue would continue to occur every couple days, but I was always able to get it back on. I finally got into the dealership, made them aware of the issue and what I've read here on the forum (mentioning replacing the wiring harness, which they didn't listen to). They have my truck for a couple days and the service tech said he was aware of the issue and that the solution was to sodder the wire, because they come crimped from the factory and it can wiggle loose. I was happy to have my truck back and to have this issue behind me... for 5 days.

This morning my truck was dead again. Per usual I wiggled the wire, but it took longer to come back on than it typically did. Was able to carefully drive to work this morning, where it died again. So obviously, not fixed, I've contacted the dealership again and I'm waiting to hear back.

Is the current thinking that just replacing the wiring harness resolves the issue?

Soldering aluminum wire ?

 

[Jcaudi]

Soldering aluminum wire ?

Not my area of expertise, just what was told by dealership. I can post a picture of the service tech notes which might clarify.

 

[Jcaudi]

I'd be curious to see what the dealership did to solder the termination on the cable. As some have posted their dealers that did a repair used a crimp fitting.

Which termination came loose on yours, the one easily visible behind the black plastic cover that tips forward, or the cable behind it?

Assuming Ford has the cable supplier providing good cables at this point a replacement should be a permanent fix.

Cheers.

I originally thought it was the easily visible one, but now I'm thinking it was the cable behind it, because that is the one I had to mess with today to get it to come on.

 

[MakinDoForNow]

I originally thought it was the easily visible one, but now I'm thinking it was the cable behind it, because that is the one I had to mess with today to get it to come on.

Question:. When the black cover is tipped forward and exposes the tab attached by the nut, is not that the tab that may be badly connected to end of the black cable which forms roughly a 90° angle at the end of the cable????

 

[Miskomd]

It’s the one behind the one in front. The cover moves to the left. Harder to access. The front one is crimped pretty well, hidden one isn’t- just a really bad solder job in it. Hard to see without unhooking the front one and removing the fuse box.

 

[mdwmd]

Another possible one here. Pulled into the driveway after a 120 mile trip, hit the stop button and everything went completely dead. No dash lights, no locks - nothing. Will start and run with jump pack, but dies immediately when the start/stop button is pressed. No issues with MPG or Deep Sleep warnings. Taking it to the dealer when they open today.

4700 miles, Lariat Lux Hybrid, 08/2021 build.

Confirmed today. new wiring harness needed, estimated time to receive parts is 2 Weeks, no loaners available until August 24th.

 

[socaljohn]

Now I have a CA lemon, it's been 45+ days and the Truck is still at the dealership. I wonder if they want to buyback so they can resell at higher profit. Lemon law attorney contacted.

Picked up truck today, drove home in 30 minutes received the deep sleep message. Asked if they checked the harness and read the information I provided and service rep said I think so, they may just recall all of them. However, they did nothing to fix the problem, tried blaming the amp, the display, the app everything but testing the harness. I am looking for a new dealership that will listen in Southern CA. Lemon law is available, but may just sell if I can get this fixed. Don't want to leave it for someone else. Carvana offered $25k, no thanks.

 

[KevCuRaoi]

Picked up truck today, drove home in 30 minutes received the deep sleep message. Asked if they checked the harness and read the information I provided and service rep said I think so, they may just recall all of them. However, they did nothing to fix the problem, tried blaming the amp, the display, the app everything but testing the harness. I am looking for a new dealership that will listen in Southern CA. Lemon law is available, but may just sell if I can get this fixed. Don't want to leave it for someone else. Carvana offered $25k, no thanks.

I really don't know if selling back as a lemon makes sense....
That dealership obviously dropped the ball. The info is out there for service departments, they just didn't look.

Find a service department that knows what they are doing. There are clear instructions on the tech hotline to either repair or replace the harness. The harness is likely backordered, but they should be able to repair and fix this problem quickly for you!

 

[skinnyboy]

I really don't know if selling back as a lemon makes sense....
That dealership obviously dropped the ball. The info is out there for service departments, they just didn't look.

Find a service department that knows what they are doing. There are clear instructions on the tech hotline to either repair or replace the harness. The harness is likely backordered, but they should be able to repair and fix this problem quickly for you!

Thanks for always posting such great information KevCuRaoi!

From your post it sounds like there is a Ford approved repair that can be made to the harness, if so that's good news.

Cheers.

 

[socaljohn]

I have called other dealerships, but want to see if we have anyone on the board that knows of one that can handle this. Just found out that I was also entitled to a loaner for the past 40+ days, the local dealership said Ford would not authorize any loaner. I have a Prius, so not that big of an issue, but just frustrating. There must be someone else in Southern CA that has had their wire harness replaced.

 

[KevCuRaoi]

Thanks for always posting such great information KevCuRaoi!

From your post it sounds like there is a Ford approved repair that can be made to the harness, if so that's good news.

Cheers.

You're welcome!

Yes, as of right now, Ford Technical Assistance is advising to repair/re-crimp/solder the loose eyelet on the cable OR replace the cable harness (if repairing is not possible). The repair / replace decision in this instance is up to the dealership.

If the tech thinks it is repairable, that is probably the best repair, since you may have to wait a month or two to get a harness!

 

[KevCuRaoi]

I have called other dealerships, but want to see if we have anyone on the board that knows of one that can handle this. Just found out that I was also entitled to a loaner for the past 40+ days, the local dealership said Ford would not authorize any loaner. I have a Prius, so not that big of an issue, but just frustrating. There must be someone else in Southern CA that has had their wire harness replaced.

If you can't find any recommendation on here...I think you will be ok if you call around and find a service manager who understands the issue and is willing to follow the recommended procedures on Ford Technical Assistance.

Ford will authorize a loaner in this case. The issue is availability. The dealership needs to have a loaner to give you. Or be able to work w/ a rental car place....they used to be willing to provide vehicles for the rates Ford pays, but that has become much more difficult lately.

If the dealership can repair the faulty connection between the eyelet and the rest of the cable, it should be a quick repair.

Good luck!

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