Wiring Harness Replaced? on a '22 Maverick Hybrid

[Love My Mav]

Has anyone had a wiring harness REPLACED rather than repaired? The dealer says replacing the harness requires quite a lot of breaking down to remove it entirely, including taking out the dash. If anyone has had to go this route, how long did it take and was it a successful fix?

For now, they've narrowed down the fault to a small length of the harness where it loses voltage that is accessible from the engine compartment. If they can find the fault, they can (hopefully) repair it. If they can't find it, then they'd have to replace the entire harness. Hoping we don't have to go there!

Ordered the truck first week of June 2021. It was built in February 2022, and we took possession in mid-April 2022.

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[MinntoMich]

My only experience is with a family members Toyota Camry Hybrid. Mice had chewed through the harness in an impossibly tight spot. Motor had to come out. Oh yeah, lots of labor. I hope they can narrow it down AND get to it easily.

 

[Love My Mav]

Thank you for responding. GOOD NEWS! When the mechanic went to inspect the wiring in the harness, an eyelet practically fell out; it was making no real contact at all. They reattached, crimped, and soldered, soldered, soldered, and wrapped tape, wrapped tape, wrapped tape. The fix makes sense in light of the failures we were experiencing, so we have very high confidence level that it really is fixed and "on the road again" as the song goes. SO HAPPY!!

Additional note - the mechanic said he was wrong about the dash having to be removed.

 

[Chris_G]

Thank you for responding. GOOD NEWS! When the mechanic went to inspect the wiring in the harness, an eyelet practically fell out; it was making no real contact at all. They reattached, crimped, and soldered, soldered, soldered, and wrapped tape, wrapped tape, wrapped tape. The fix makes sense in light of the failures we were experiencing, so we have very high confidence level that it really is fixed and "on the road again" as the song goes. SO HAPPY!!

Additional note - the mechanic said he was wrong about the dash having to be removed.

Glad that you got a honest answer.

 

[son of a ..sven]

How many other "mistakes" have happened in the rush of producing Mavericks? Quality control?

 

[Chris_G]

How many other "mistakes" have happened in the rush of producing Mavericks? Quality control?

Ford doesn't make mistakes, only recalls

 

[KeinoDoggy]

Thank you for responding. GOOD NEWS! When the mechanic went to inspect the wiring in the harness, an eyelet practically fell out; it was making no real contact at all. They reattached, crimped, and soldered, soldered, soldered, and wrapped tape, wrapped tape, wrapped tape. The fix makes sense in light of the failures we were experiencing, so we have very high confidence level that it really is fixed and "on the road again" as the song goes. SO HAPPY!!

Additional note - the mechanic said he was wrong about the dash having to be removed.

Hate to be the one to throw water on you but I and others here would be a little concerned about the patch job they did. It appears that the wiring itself is aluminum not copper. So soldering a copper lug to an aluminum wire is not a good idea. The TSB clearly states that the entire harness is to be replaced. If I were you, I would go back to the dealer point this out to them and have them order the harness replacement so that the repair can be resolved as intended by Ford. Read through the following thread on this issue in it's entirety.

https://www.mavericktruckclub.com/f...-no-start-crank-repair-excellent-video.20210/

 

[son of a ..sven]

Ford doesn't make mistakes, only recalls

Ford has been producing vehicles for over 100 years. One (this one ) would think they have production running as well as it is possible. As an aside, Tesla, which has been producing, well, at first very slowly but producing vehicles about 12 years. Their quality control is terrible and that is an improvement of what it has been. Body panes with inconsistent gaps, etc,etc.etc.
My conclusion, that Ford hyped the Maverick (really, the Hybrid ) and rushed to get it to market. Now they saw they never planed to produce more that 35% of What They Expected.
I have had Ford products for 45+ years, our family was a Ford family..My father raced Fords in the 40's.
I have completely lost faith in the company.

 

[Love My Mav]

Thanks for all the input. The dealer had to get approval from Ford before they attempted to repair the harness, so they're not sidestepping Ford's directives. As I understand it, the harnesses continue to be on lengthy backorders. Even if the harness were replaced rather than repaired, how would we know if the replacement harness has been upgraded to copper from aluminum wire? How could we be sure that the replacement part doesn't have the same faulty soldering? We're okay with the repair and hopeful, of course, that there will be no further issues. If a future failure occurs, then I would think that replacement would be Ford's only option at that point.

 

[Gullzway]

Thank you for responding. GOOD NEWS! When the mechanic went to inspect the wiring in the harness, an eyelet practically fell out; it was making no real contact at all. They reattached, crimped, and soldered, soldered, soldered, and wrapped tape, wrapped tape, wrapped tape. The fix makes sense in light of the failures we were experiencing, so we have very high confidence level that it really is fixed and "on the road again" as the song goes. SO HAPPY!!

Additional note - the mechanic said he was wrong about the dash having to be removed.

Is this still working out well for you?
I'm seriously considering replacing that lug on my harness, I bought one last year when these issues were popping up.

Tried to take my truck in for the CSP on the wiring harness and it's been a month now, I can barely get the dealer to communicate. Scheduled the appointment, took my truck in a week later, they didn't order the part till 3 days after that. Didn't hear from them for 2 weeks called and neither the service department or parts department can tell me if they've ordered the part or find the ticket from my service.

 

[Hardening2753]

Is this still working out well for you?
I'm seriously considering replacing that lug on my harness, I bought one last year when these issues were popping up.

Tried to take my truck in for the CSP on the wiring harness and it's been a month now, I can barely get the dealer to communicate. Scheduled the appointment, took my truck in a week later, they didn't order the part till 3 days after that. Didn't hear from them for 2 weeks called and neither the service department or parts department can tell me if they've ordered the part or find the ticket from my service.

Take it to a different dealership

 

[Krrr]

Yes, try a differant spot. They are out there. Just like the axles.

 

[Gullzway]

Take it to a different dealership

That's my next plan, but I've heard similar stories from every Ford dealership in the area.

 

[golfguy2020]

I just had this done monday

I got the letter a couple weeks ago about 'customer service program' or whatever its called and the dealer first tried to say it was an extended warranty for that part for 1 year but mentioned 2024 which would still be under the 3 year/60k so that didn't make sense

finally they said they would just do it (even though I wasn't experiencing symptoms of no start yet)

so they ordered the cable, it came in and I dropped car off Monday morning at 8am

they did the cable service/recall, updated/program ecm for emissions recall and did an oil change and were done by 4pm

 

[golfguy2020]

Additional note - the mechanic said he was wrong about the dash having to be removed.

the dash doesn't have to be removed but they have to take out/remove the door sill trim and the rear under seat storage - I emptied mine out and threw it all in the bed the night before

on reddit maverick forum someone posted pictures of the job being done

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