Maverick Hybrid Brakes Completely Ruined After Towed Behind RV

[todd92]

I'm baffled how the brake assist could have applied enough brake force to completely ruin the brakes yet you didn't notice and drag while towing?

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[colinl]

I'm baffled how the brake assist could have applied enough brake force to completely ruin the brakes yet you didn't notice and drag while towing?

my theory is that the battery voltage fell below 11.8 and the truck shut down and fell out of neutral tow.

that's not an uncommon thing to happen.

 

[VBMav]

We used the Blue Ox tow bar system and the Stay-N-Play Duo controller (installed by it's previous manufacturer, not a dealer, because it was invented and made here in the Evansville, IN area). It was installed in our 2012 Chevy Sonic and worked well for the 2 or 3 years we had the gas-powered RV.

Based on that experience, I was wondering if the adjusting knob on the in-cab controller by your left foot had be knocked out of it's middle position to cause the towed vehicle brakes to apply sooner or harder? (This is on the same small box as the off-on toggle switch.)

We no longer have our motorhome but the Stay-N-Play system is still installed in the Sonic and hasn't caused any trouble that we are aware of.

 

[1929]

my theory is that the battery voltage fell below 11.8 and the truck shut down and fell out of neutral tow.

that's not an uncommon thing to happen.

This is my theory also.

 

[Archivist Engineer]

my theory is that the battery voltage fell below 11.8 and the truck shut down and fell out of neutral tow.

that's not an uncommon thing to happen.

Who could have guessed that cheapening out and installing a battery with less capacity than what the truck was designed around would causes issues down the road? Especially after Ford sent two years refusing to acknowledge there have been repeated issues stemming from this decision.

Best explanation of why these issues are occurring can be found here.

As to why they have refused to acknowledge this issue, someone posted that in order to change the battery size or type, they would have to resubmit the vehicle to have the fuel economy recertified. Which if true, there's no way that's going to happen, hence the refusal to acknowledge the battery issue.

Also, make sure to report the incident to the to the NHTSA, especially the fact that it's a safety issue and Ford is refusing to honor their warranty.

 

[colinl]

Who could have guessed that cheapening out and installing a battery with less capacity than what the truck was designed around would causes issues down the road? Especially after Ford sent two years refusing to acknowledge there have been repeated issues stemming from this decision.

Best explanation of why these issues are occurring can be found here.

As to why they have refused to acknowledge this issue, someone posted that in order to change the battery size or type, they would have to resubmit the vehicle to have the fuel economy recertified. Which if true, there's no way that's going to happen, hence the refusal to acknowledge the battery issue.

Also, make sure to report the incident to the to the NHTSA, especially the fact that it's a safety issue and Ford is refusing to honor their warranty.

Good luck.

I'm also a Bronco owner but don't flat tow anything, so my information is peripheral and direct experience non-existent.

But I have most definitely seen a number of Broncos severely damaged because they also have a flat tow mode, and they also fall out of it when the 12V battery voltage falls.

If Ford should change anything it should be the manual. RECOMMEND OWNERS TO INSTALL RV-BASED CHARGING. Warn them that if the battery voltage sags below a certain level that the vehicle will exit flat tow mode and can/will be severely damaged.

This is literally what the Maverick manual says, the only thing that looks somewhat like a battery voltage warning, and I think it's woefully inadequate.

Note: Start your vehicle at the beginning of each day, and every six hours or fewer. With the vehicle on and your foot on the brake, shift into drive (D) and then back into Neutral (N). Before continuing to tow, switch neutral tow on and keep the vehicle on for three minutes.

 

[Wanderlust]

Sorry to hear this brother I have towed my Maverick for a year now with no problems so far. I would recommend if your going to tow anything call Etrailer they are experts in anything to do with towing your Maverick’s. I have roadmaster equipment tow bar,brake,rock guard. I pray you solve your problems with no cost to you.

Thank you so much, Don. That's a good call to talk to ETrailer. I have used them in the past for guidance.

 

[Wanderlust]

do you have an auxiliary charger from the RV to the Maverick?

if not, are you certain the battery level in the Maverick was sufficient?

Yes - the installer of the Demco braking system put in a battery charge line and the battery was not dead when we finished towing and unhitched.

 

[colinl]

Yes - the installer of the Demco braking system put in a battery charge line and the battery was not dead when we finished towing and unhitched.

that changes everything for me.

I think it probably was some kind of failure or installation issue with the RV braking system.

 

[Archivist Engineer]

Good luck.

I'm also a Bronco owner but don't flat tow anything, so my information is peripheral and direct experience non-existent.

But I have most definitely seen a number of Broncos severely damaged because they also have a flat tow mode, and they also fall out of it when the 12V battery voltage falls.

If Ford should change anything it should be the manual. RECOMMEND OWNERS TO INSTALL RV-BASED CHARGING. Warn them that if the battery voltage sags below a certain level that the vehicle will exit flat tow mode and can/will be severely damaged.

This is literally what the Maverick manual says, the only thing that looks somewhat like a battery voltage warning, and I think it's woefully inadequate.

Note: Start your vehicle at the beginning of each day, and every six hours or fewer. With the vehicle on and your foot on the brake, shift into drive (D) and then back into Neutral (N). Before continuing to tow, switch neutral tow on and keep the vehicle on for three minutes.

I mean, if they're going to update the manual, they should at least be honest then.

Warning: Because we chose to install an under capacity battery of a different type than this vehicle was designed for, the voltage may fall below the required level at any time, including while the vehicle is running and actively charging said battery. If this happens while the vehicle is being towed, it will severely damage the vehicle and we will deny the warranty claim.

 

[Wanderlust]

that changes everything for me.

I think it probably was some kind of failure or installation issue with the RV braking system.

Just got off the phone with Demco - the engineers believe that the disintegration of the brakes was not a result of the malfunction of the Stay-In-Play braking system but an installation issue. They believe that the system was not mounted correctly (Ford noticed it was anchored on the airbag) and that overtime the actuator eventually got stuck - and continued depressing the brakes - and the cable snapped off actuator. The Demco engineer is going to contact the installer and we will take it from there. Sure hoping they will take responsibility for this costly damage.

 

[Montana]

Just got off the phone with Demco - the engineers believe that the disintegration of the brakes was not a result of the malfunction of the Stay-In-Play braking system but an installation issue. They believe that the system was not mounted correctly (Ford noticed it was anchored on the airbag) and that overtime the actuator eventually got stuck - and continued depressing the brakes - and the cable snapped off actuator. The Demco engineer is going to contact the installer and we will take it from there. Sure hoping they will take responsibility for this costly damage.

At least it's been narrowed down. Still, as others mentioned, a bit scary thinking the system could be faulty if the battery drops below a certain voltage which is well known on these trucks. Am I understanding that correctly?

 

[processwrench]

Just got off the phone with Demco - the engineers believe that the disintegration of the brakes was not a result of the malfunction of the Stay-In-Play braking system but an installation issue. They believe that the system was not mounted correctly (Ford noticed it was anchored on the airbag) and that overtime the actuator eventually got stuck - and continued depressing the brakes - and the cable snapped off actuator. The Demco engineer is going to contact the installer and we will take it from there. Sure hoping they will take responsibility for this costly damage.

Since this is the sytem I am planning on installing on my mav, would you have a picture of the incorrect mounting? Just so i know NOT to do that.

 

[rmhopper]

I have the Demco brake system, but have only about 500 toad miles on it. As described elsewhere in the forum, I was concerned about the amount of air pressure on the brake system and how hard the brakes were being applied even at low speed, so I installed a regulator to back down the pressure. I'll certainly be watching the brakes regularly from here on out (I have been checking the wheels for excessive heat at each stop). Wondering if I should put in a hub temp sensor on the Maverick...

 

[The Real Maverick]

my theory is that the battery voltage fell below 11.8 and the truck shut down and fell out of neutral tow.

that's not an uncommon thing to happen.

Plausible.

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