Video: Hybrid Wiring Harness Failure (No Start / Crank) Repair. Excellent video

[KeinoDoggy]

Is it aluminum wire or tinned copper wire?

Aluminum

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[MichaelG]

I hope hes not using that copper lug on that aluminum wire cable, that is a huge fail.
And if the dealer is putting these in repaired Mavs its a big mistake, its not IEEE code, and to speak frankly its a fire hazard.

Check out what happened in the 60s and 70s with aluminum wiring in contact with copper. Some houses burned...

Hes a good tech, but a bad metallurgical tech.

I watched his video last night and saw it was the connector where he missed the 3v at the fusebox.

Yep, big mistake joining copper directly to aluminum.

Correct way to join Cu to Al

 

[JBL14]

Aluminum

Could it be an aluminum alloy??
https://global-sei.com/technology/tr/bn84/pdf/84-22.pdf

Still, they make aluminum crimps....
https://www.grainger.com/product/THOMAS-BETTS-One-Hole-Lug-Compression-Connector-1XRA4

 

[MakinDoForNow]

Ok ALL! With all the plated connectors and all the high amperage circuits. I would totally expect the wire to be Cupro nickle (706?). If so then would have to be deoxidized immediately prior to silver soldering with sparingly fluxing and acid removing joint contamination after the soldering. If a barrel connector is used can it be properly deoxidized, soldered, and cleaned. That's probably why Ford has the flat solder joint in the design. Most likely there was a manufacturing error in the procedure when the soldered joint was prepared. I expect that to properly solder that tab back into wire the harness would have to be removed to avoid risk of damage to area around the work zone.

 

[skinnyboy]

So simple. Crimp a damn lug on from the factory Ford. There is absolutely no logical reason to do what you did. It was a very ignorant decision.

Side note. I planned on doing this exact fix as soon as my hybrid arrives. Already have a crimper but I’ll need some aluminum lugs.

Might be a tight squeeze getting that sucker in there

Cheers.

 

[Bmr4mav]

Might be a tight squeeze getting that sucker in there

Cheers.

He fit his larger hydraulic crimper in there. The arms on mine don't have to open wide to fit over the lug.

 

[huunvubu]

I hope he's not using that copper lug on that aluminum wire cable, that is a huge fail.
And if the dealer is putting these in repaired Mavs it's a big mistake, it's not IEEE code, and to speak frankly it's a fire hazard.

Check out what happened in the 60s and 70s with aluminum wiring in contact with copper. Some houses burned...

He's a good tech, but a bad metallurgical tech.

I watched his video last night and saw it was the connector where he missed the 3v at the fusebox.

Yep, big mistake joining copper directly to aluminum.

Correct way to join Cu to Al

You must have missed that this is a temporary fix (mentioned in the video) for the owner of the Maverick so they can drive their Maverick until the ordered replacement of the wiring harness and fuse box arrives. When the replacement parts do arrive they will replace this temporary fix.

 

[skinnyboy]

He fit his larger hydraulic crimper in there. The arms on mine don't have to open wide to fit over the lug.

Looked up the type of crimper he used on Amazon, it crimps along its axis hydraulically so the head of the crimper doesn't look as wide.

Haven't had mine out to check it yet, but had the fuse box out to check access, and I don't think any crimper will fit without the DC-DC inverter moved.

Not trying to be negative, just sharing what I've seen when assessing mine.

Cheers.

 

[Hybrid Nut]

One of the most honest and knowledgeable techs I have seen on YouTube

Thats what i said from the beginning. Why do they have to replace the entire harness when they can just replace the end. Which is the only bad part of the harness. People replace cable ends all the time. its just a 12volt cable. Should be easy fix for dealer or DIY at home unless it voids warranty if you do it yourself.. Thanks for great video.

 

[FriscoTXJoe]

God my sales guy head hurts reading all the details MTC folks have added. Thank you.
Now if I can find someone in the DFW who know's what they are doing, I will gladly compensate you if you want to do this to my hybrid before I have an issue.

 

[huunvubu]

I'll bet he feels better about this Mechanic's fix, than I feel right now about my early March of 22 build.

Have watched his vids for about a year now. He has really good vids, and some mindless rants. Oh, the life of the paid by the job technicians.

You have been B U R N E D

 

[Mach 1]

Here's my write up if you want to use it for tools and what I saw.

https://www.mavericktruckclub.com/forum/threads/hybrid-battery-cable-lug-inspect.20063/

Huun, I guess you didn't read my post, you never ever join copper and aluminum touching together and then run electricity through it.

What happens if the customer figures, oh its working good, I will just keep driving it.

 

[Mach 1]

I think members are misunderstanding the type of connection needed. While yes a tight connection is required for a MECHANICAL connection, what we are looking for here is much more then that. We are primary concerned, about an electrical connection.

 

[Mach 1]

Why crimp when you dont have to?

 

[OXHB619]

I think members are misunderstanding the type of connection needed.

I am not a certified tech, so I will defer to the guy that has a channel dedicated to sharing his expertise.

Not going to fix it when mines arrives either, I will wait on Ford. I carry a jump pack, minor inconvenience at best.

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