CSP 22B39: Hybrid Maverick No Start Condition issue affecting 21,513 vehicles (Customer Satisfaction Program / Delivery Hold)

[Exranger]

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[Riposterous]

Anyone who has had 22B39 performed have any issues with how their dealer performed the service? Anything I need to watch for with the dealer technicians workmanship?

Yes, I had an issue that I forgot to mention right after the first time the dealer installed the cable. A no-start situation occurred again three days after I got the truck back, so I jumped it and took it back to the dealer. Not sure if what the manager told me is true or not, but he claimed the worker who finally fixed it properly looked at everything along the entire path of the wiring and concluded that the previous worker had missed three stupid-obvious things. First, that the new wire end connector in the engine bay had a part of its semi-ridged thin crunchy plastic casing/shell stuck between the connection points (I believe this, because I saw how messy, overhanging, and somewhat mangled that plastic looked the first time I got it back), so he trimmed it properly, second, that the metal connector itself had some sort of lumpy glue-substance on it on it which he then removed, and that lastly, the connection had not even been properly tightened! I don't know if the first guy works there anymore or what, but the manager apologized quite a bit for the stupid screw-ups.

Anyway, no problems at all since getting it back on July 19th. Next stop, the potential engine bay fire recall (provided they don't delay it again).

 

[SuperTongue]

Anyone who has had 22B39 performed have any issues with how their dealer performed the service? Anything I need to watch for with the dealer technicians workmanship?

Chiming in that it’s been a few months now since I had this done and no issues. I fortunately never got the no start condition on my February 2022 build but the dealer performed the service no questions asked. Pretty painless for the peace of mind having it done offered.

I had more issues with the airbag recall than this. And that was just scratches on the dash that eventually ended in getting the entire dash panel replaced.

 

[flashfearless]

Yes, I had an issue that I forgot to mention right after the first time the dealer installed the cable. A no-start situation occurred again three days after I got the truck back, so I jumped it and took it back to the dealer. Not sure if what the manager told me is true or not, but he claimed the worker who finally fixed it properly looked at everything along the entire path of the wiring and concluded that the previous worker had missed three stupid-obvious things. First, that the new wire end connector in the engine bay had a part of its semi-ridged thin crunchy plastic casing/shell stuck between the connection points (I believe this, because I saw how messy, overhanging, and somewhat mangled that plastic looked the first time I got it back), so he trimmed it properly, second, that the metal connector itself had some sort of lumpy glue-substance on it on it which he then removed, and that lastly, the connection had not even been properly tightened! I don't know if the first guy works there anymore or what, but the manager apologized quite a bit for the stupid screw-ups.

Anyway, no problems at all since getting it back on July 19th. Next stop, the potential engine bay fire recall (provided they don't delay it again).

My truck is at the dealer right now, it's 3 PM and it has been there all day. Called for a status update and was told the tech still had the interior all out. I hadn't really thought about them having to take the whole interior out? Maybe I should've skipped this.

It's Friday and it's 3:22. Don't know if I will have it for the weekend.

 

[Riposterous]

Sigh. Here we are just a bit past the four-month mark since the last no-start condition and the Maverick will not start again.
And of course it had to happen yesterday on Thanksgiving.

Same problem as always, as if nothing was ever fixed. Vehicle completely dead, so I opened the hood, hooked up my NOCO Boost, turned the key and it started immediately. And just to be clear, the day before this issue, I drove 9.4 miles non-stop before parking it in the garage, so it should have been fully charged.

Put simply, the replacement battery did not fix this issue. Ford's new battery cable did not fix this issue. Cleaning the connection points and re-tightening things did not fix the issue. The problem lies somewhere else, and apparently, nobody knows how to fix it. The situation is so bad that I'm thinking about giving up on Ford and moving on to Honda or Toyota. Maybe I can invoke our lemon law at this point, I don't know. I don't want to do any of this, as I like Ford and have owned quite a few Ford products, new & used, in my life....but I clearly cannot trust this vehicle after this many dealership attempts (4 times, I think? - I've lost count) to correct the issue, with no improvement at all.

Anyway, sorry for the rant, but I'm just so incredibly disheartened and frustrated by all of this.

 

[GhostMav]

Sigh. Here we are just a bit past the four-month mark since the last no-start condition and the Maverick will not start again.
And of course it had to happen yesterday on Thanksgiving.

Same problem as always, as if nothing was ever fixed. Vehicle completely dead, so I opened the hood, hooked up my NOCO Boost, turned the key and it started immediately. And just to be clear, the day before this issue, I drove 9.4 miles non-stop before parking it in the garage, so it should have been fully charged.

Put simply, the replacement battery did not fix this issue. Ford's new battery cable did not fix this issue. Cleaning the connection points and re-tightening things did not fix the issue. The problem lies somewhere else, and apparently, nobody knows how to fix it. The situation is so bad that I'm thinking about giving up on Ford and moving on to Honda or Toyota. Maybe I can invoke our lemon law at this point, I don't know. I don't want to do any of this, as I like Ford and have owned quite a few Ford products, new & used, in my life....but I clearly cannot trust this vehicle after this many dealership attempts (4 times, I think? - I've lost count) to correct the issue, with no improvement at all.

Anyway, sorry for the rant, but I'm just so incredibly disheartened and frustrated by all of this.

Mine is having the same issue now. MY 23.

 

[icegradner]

While I've never had a no start problem, 12v battery drain has been an issue, so I had this program done on my Maverick this week. Took them 3 1/2 days, some of it waiting for parts. They replaced the cable, and after testing the 12v charge system they also replaced a 300A fuse under the hood. I believe other people here noted having that fuse replaced as well.

 

[jsus]

They replaced the cable, and after testing the 12v charge system they also replaced a 300A fuse under the hood. I believe other people here noted having that fuse replaced as well.

Yes, see thread: https://www.mavericktruckclub.com/f...-hybrid-12v-volt-battery-drain-problem.31260/

There has been some mention posted on here about 12 volt( low voltage system) battery drain and " deep sleep" messages from Ford Pass in Mavericks, today Ford released on the Professional Technician System accessible by Ford technicians this special service message, this may be something to have your dealer check if you are experiencing the problem of no start or dead/low battery. It does not specify that the mega fuse is being " blown" or popped, from my experience as a technician with some of the other models I have seen this mega fuse actually develop a crack ( typically caused by road shock/vibration)which can intermittently allow the loss of electrical charge to the battery, I've had them where they test good with an ohm/continuity meter laying on a bench but then with a little pressure applied to each end will test open. Ford does listen and research complaints/concerns with their vehicles and typically will give us( technicians) a heads up once they find a repetitive cause. Here is the service message, hope it helps some of you!

​

May 4 2023 New SSM 51598 2020-2023 Escape/Corsair, 2022-2023 Maverick – FHEV/PHEV - 12V Battery Voltage Low Or Discharged With DTC U3003:62 Stored In The DC/DC

Some 2020-2023 Escape/Corsair equipped with 2.5L engine full hybrid electric vehicle (FHEV) and plug-in hybrid electric vehicle (PHEV) powertrain and 2022-2023 Maverick vehicles equipped with 2.5L engine FHEV powertrain may exhibit a condition where the 12V battery voltage is low or discharged with diagnostic trouble code (DTC) U3003:62 stored in the direct current/direct current converter control module (DC/DC). The vehicle may also exhibit DTC U3003:16 and/or U3000:04 stored in the DC/DC module. This may be due to an open in the 300 amp mega fuse located in the high current battery junction box (BJB). To correct this condition, refer to Workshop Manual (WSM), Section 414-05>Pinpoint Test H1 to verify the 300amp mega fuse condition, replace the fuse upon confirmation it is open. Test and recharge the 12v battery.

 

[Riposterous]

So, while I'm waiting for my repair appointment on Tuesday, I thought it might be a good idea to open the hood and hook up the NOCO Boost to get the truck up & running and drive it a five or ten miles to see if I could get it to hold a charge at least until then.
No luck. For the first time, that won't even work. Truck is 100% dead. Unless there's another trick to try, I guess it's time for Ford to foot the bill for more towing.

 

[icegradner]

So, while I'm waiting for my repair appointment on Tuesday, I thought it might be a good idea to open the hood and hook up the NOCO Boost to get the truck up & running and drive it a five or ten miles to see if I could get it to hold a charge at least until then.
No luck. For the first time, that won't even work. Truck is 100% dead. Unless there's another trick to try, I guess it's time for Ford to foot the bill for more towing.

Did you follow the procedure for forcing the NOCO to charge the battery if it is in a very low state of charge? If the battery is very low it may not work without doing so.

 

[Riposterous]

Did you follow the procedure for forcing the NOCO to charge the battery if it is in a very low state of charge? If the battery is very low it may not work without doing so.

Thank you! Previously, I had attempted to get it running this way, but when I had held the (!) button down, I had no luck. This time it worked perfectly. I had somehow missed the part about waiting for the lights to enter a chase pattern, and likely just didn't keep the button fully depressed long enough.
Next stop, the dealership on Tuesday.

 

[johnpbrewer]

Sigh. Here we are just a bit past the four-month mark since the last no-start condition and the Maverick will not start again.
And of course it had to happen yesterday on Thanksgiving.

Same problem as always, as if nothing was ever fixed. Vehicle completely dead, so I opened the hood, hooked up my NOCO Boost, turned the key and it started immediately. And just to be clear, the day before this issue, I drove 9.4 miles non-stop before parking it in the garage, so it should have been fully charged.

Put simply, the replacement battery did not fix this issue. Ford's new battery cable did not fix this issue. Cleaning the connection points and re-tightening things did not fix the issue. The problem lies somewhere else, and apparently, nobody knows how to fix it. The situation is so bad that I'm thinking about giving up on Ford and moving on to Honda or Toyota. Maybe I can invoke our lemon law at this point, I don't know. I don't want to do any of this, as I like Ford and have owned quite a few Ford products, new & used, in my life....but I clearly cannot trust this vehicle after this many dealership attempts (4 times, I think? - I've lost count) to correct the issue, with no improvement at all.

Anyway, sorry for the rant, but I'm just so incredibly disheartened and frustrated by all of this.

Mine has been at the dealer for 5 months now trying to fix this issue. Only got to drive it two months. They have replaced everything -- fuse, cable, battery (twice), and now the dc/dc converter. Ford engineer is coming in Wednesday. You aren't the only one with this problem. Ford may offer to reimburse/buy back the vehicle, but it will be a crap offer. It would cost me an extra ~$8000 on top of what they offered to get the same equivalent vehicle that I bought under warranty and only got to drive for two months.

 

[Riposterous]

Well, the truck is back from the dealership. Diagnosis? - bad battery...again. They also re-programmed the powertrain control module. The new battery is now the fourth in the vehicle (the other three were all replaced at various points over 2023). I can't complain about the two dealerships we've dealt with, as they've been nothing but sympathetic and supposedly tested for or applied every recall/TSB/whatever else out there at this point, and made sure we had loaner vehicles each time this has happened.

So, we drove it back home. My wife and I talked to Ford customer service afterwards to remind them of the extent of this issue, and hear what they had to say about resolving this. They are now offering us two options: to send an engineer to the dealership if we have the issue again, or begin a buyback process. We're still deciding as to what to do.

Again, this is all so disappointing, because other than this singular glaring problem, we absolutely love this truck and haven't had any other issues with it.

 

[johnpbrewer]

Well, the truck is back from the dealership. Diagnosis? - bad battery...again. They also re-programmed the powertrain control module. The new battery is now the fourth in the vehicle (the other three were all replaced at various points over 2023). I can't complain about the two dealerships we've dealt with, as they've been nothing but sympathetic and supposedly tested for or applied every recall/TSB/whatever else out there at this point, and made sure we had loaner vehicles each time this has happened.

So, we drove it back home. My wife and I talked to Ford customer service afterwards to remind them of the extent of this issue, and hear what they had to say about resolving this. They are now offering us two options: to send an engineer to the dealership if we have the issue again, or begin a buyback process. We're still deciding as to what to do.

Again, this is all so disappointing, because other than this singular glaring problem, we absolutely love this truck and haven't had any other issues with it.

I had a similar problem. They replaced the battery a couple times, the 3A fuse, the cable, dc/dc converter (this per Ford FSE). None fixed it. The Ford engineer came down again and diagnosed a loose fuse box or fuse or something like that. Reseated properly and it corrected the issue. Apparently his diagnostic tools are better than the dealerships? I had a special offer to buy back, but it was a bad offer. Would have cost me an extra $8000 or so to replace my Hybrid XLT with an equivalent Hybrid XLT. I ordered in Oct 2021 and pricing and options have changed since then. I would have the Ford FSE come and try to fix it, before entertaining any buy back offer. Just got my truck back. Hope this really fixed the problem.

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