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Dead Maverick Hybrid? Try this… EDIT - Never mind!

thosw

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EDIT… My luck ran out! I have to use my jump pack now.


Like many of you, my Maverick Hybrid has begun to go completely dead (no start, no lights, no screen, no power anything) intermittently after 10 months of ownership (but with VERY low mileage) and my dealer has the replacement wiring harness on order for me.

For context, I have the Lariat Hybrid with push-button start/stop. I have been receiving regular Deep Sleep messages for the past couple of months, but had not experienced a condition that prevented my truck from operating until recently. In my case, the vehicle only goes dead at the end of operation when I push the Stop button. I have never had a condition whereby the truck would not start after a normal shutdown sequence - even when the truck is in an obvious Deep Sleep mode.

I was fortunate that the first Dead condition occurred when I returned to my garage and pushed the Stop button. I raised the hood and jiggled wires to no effect. Then I detached the vertical Black plastic latch cover located just to the left of the horizontal Red plastic cover for the 12 Volt jump terminal. I believe this Black cover is over the power supply to the high voltage battery. When I snapped the Black terminal cover back shut, the truck immediately energized and I was able to start it again. I figured this was just dumb luck.

A few days later, I experienced another Dead condition at shutdown. I was away from home this time. So before reaching for my jump box, I thought I would try the Black latch cover again. To my astonishment, the truck sprung to life again as soon as the cover clicked closed.

As I write this, I have had six (6) Dead conditions and each time the truck has re-energized when the cover clicks shut. There is no pressure applied - it is as if the frequency of the “click” sound of the cover latch closing causes the truck to re-energize. I know this makes no sense, but this is what is happening in my case.

Whether or not it will work for you, I have no idea. But before you jump start your truck, give this a try.
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uga

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Its a faulty connector, just have the dealer replace/repair the connector.
 
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thosw

thosw

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Its a faulty connector, just have the dealer replace/repair the connector.
The dealership said that since this problem has been addressed in a Ford TSB, they are obligated to follow the instructions in the TSB to perform the repair. The wiring harness is to be replaced per the TSB.
 

uga

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The dealership said that since this problem has been addressed in a Ford TSB, they are obligated to follow the instructions in the TSB to perform the repair. The wiring harness is to be replaced per the TSB.
Dealership near me has replaced the connectors on approx 7 instead of waiting for the harness. This was done before the TSB. Perhaps they are replacing the entire harness now, not an easy job.

Ford Maverick Dead Maverick Hybrid? Try this… EDIT - Never mind! Snap1
 
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thosw

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Dealership near me has replaced the connectors on approx 7 instead of waiting for the harness. This was done before the TSB. Perhaps they are replacing the entire harness now, not an easy job.

Snap1.jpg
Same as my dealership… but since the TSB came out, there must be a problem for the dealership submitting a warranty claim for labor reimbursement if the repairs do not follow the official procedure. My dealer didn’t specifically state this, but that was the impression I got.
 

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uga

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Gotcha!

So what is the wait time for the harness these days? It was on backorder.
 
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thosw

thosw

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Gotcha!

So what is the wait time for the harness these days? It was on backorder.
They ordered mine on 10/14… at that time I was quoted 3-4 weeks, but could change.
 

uga

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At the very least you would think they would put a new connector on while waiting, its a very simple fix...............................

Did they give you have a loaner car/truck ?
 
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thosw

thosw

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At the very least you would think they would put a new connector on while waiting, its a very simple fix...............................

Did they give you have a loaner car/truck ?
No, I’m still driving mine until the part comes in. I’m told the repair can then be accomplished on the same day the truck is dropped off. They only furnish loaners for repairs that require more than one business day and are subject to availability. I have no problem driving my truck now until the parts arrive… in fact, I prefer to do that unless something drastically changes.
 
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thosw

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Gotcha!

So what is the wait time for the harness these days? It was on backorder.
I had an update from my dealer yesterday (11/8/22) concerning the Hybrid wiring harness replacement availability. According to my dealer, a shipment of 600 wiring harnesses are in route to Ford, and dealers with the 600 oldest orders should receive their replacement harness sometime next week (11/14 - 11/19). He also stated there are currently in excess of 1000 orders for the harness, so there will still be people waiting until another shipment. Hopefully I’ll be one of the lucky 600.
 
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This is lame. It’s almost a year now and still no recall on this. TSB is such bullshit especially if your Maverick is broke down when you’re further away from home.
 

Chris_G

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Hello,

I've joined the dead Maverick club, thanks for the invite.

Wire is copper stranded. Appears to be soldered at the very end of the connector, i.e. cold solder joint.

Replaced with new AL/CU crimp connector. Now I need to reset check engine indicator.
 

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Wire is copper stranded. Appears to be soldered at the very end of the connector, i.e. cold solder joint.
Don't suppose you happened to have any of the cable leftover you could shoot a picture of to corroborate it was copper core? There was a lot of handwringing over the cable potentially being aluminum and concerns about galvanic corrosion with dealers installing copper lugs as replacement. One member that replaced it themselves said there's was aluminum.
 

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Don't suppose you happened to have any of the cable leftover you could shoot a picture of to corroborate it was copper core? There was a lot of handwringing over the cable potentially being aluminum and concerns about galvanic corrosion with dealers installing copper lugs as replacement. One member that replaced it themselves said there's was aluminum.
Ford Maverick Dead Maverick Hybrid? Try this… EDIT - Never mind! 20221128_081218
 

MakinDoForNow

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Don't suppose you happened to have any of the cable leftover you could shoot a picture of to corroborate it was copper core? There was a lot of handwringing over the cable potentially being aluminum and concerns about galvanic corrosion with dealers installing copper lugs as replacement. One member that replaced it themselves said there's was aluminum.
A picture would be interesting but without an analysis of it would mean little. I would certainly expect with a ten year hybrid warranty it should be a cupronickel, cupronickel coated aluminum alloy or cupronickel coated copper wire. Particularly with the type of solder joint which appears appears to be failing. How about someone fetches one off a wrecked maverick and has it tested? I expect a manufacturing error has been discovered and has been corrected so it would be best to only test one which has failed.
Well the picture certainly appears to be copper.
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