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Online research of my Mav hybrid problems: no-start, “stop safely now” message, red triangle, MIL, and battery warning lamps with DTCs P1A10 and P0C78, resulted in finding a TSB 22-2178 issued on 8-1-2022 for the Ford Mach-E (MachEForum.com). Although I understand the Mach-E is a full EV and the Maverick is a hybrid (HEV), both vehicles have high voltage and 12v battery systems, with associated junction boxes, contactors, battery control modules and wiring harnesses. The issues described in the TSB are virtually the same as what I experienced. Note also the affected build dates include my build date. The full TSB is below, with my symptoms highlighted in yellow.
My History:
Maverick hybrid, XLT, lux, copilot 360. Ordered 8-26-2021. Built 5-19-2022. Received/purchased 7-22-2022.
7-30-2022: Received ford pass message “remote features disabled to preserve battery”. Note that this was after driving 160 miles the previous day. 12v battery voltage measured 12.37v. Truck started and drove normally. While running, 12v battery voltage was 14.7v.
8-10-2022: Experienced no-start, displaying “stop safely now” message, red triangle, MIL, and battery warning lamps. Retried every 15 minutes for an hour before using ford pass to call for tow. Tow truck arrived in 30 minutes. I tried to start one more time and it went into ready mode (ie started) and I drove home. Scheduled 12v battery testing for 8-12-2022.
8-12-2022: Dealer performed battery test - Passed. Scheduled diagnostic testing for 8-22-2022.
8-22-2022: Dealer pulled DTCs P1A10 and P0C78 and performed pin test - Passed.
8-26-2022: Picked up truck. Drove normally.
8-27-2022: My ford customer experience agent called me (on a Saturday). She confirmed that Ford engineering had initiated a hotline with the dealer service tech on 8-22, presumably to walk through the pin testing. She indicated that she did not talk directly with engineering as they are not “customer facing” and that engineering only communicated with dealer service techs.
My History:
Maverick hybrid, XLT, lux, copilot 360. Ordered 8-26-2021. Built 5-19-2022. Received/purchased 7-22-2022.
7-30-2022: Received ford pass message “remote features disabled to preserve battery”. Note that this was after driving 160 miles the previous day. 12v battery voltage measured 12.37v. Truck started and drove normally. While running, 12v battery voltage was 14.7v.
8-10-2022: Experienced no-start, displaying “stop safely now” message, red triangle, MIL, and battery warning lamps. Retried every 15 minutes for an hour before using ford pass to call for tow. Tow truck arrived in 30 minutes. I tried to start one more time and it went into ready mode (ie started) and I drove home. Scheduled 12v battery testing for 8-12-2022.
8-12-2022: Dealer performed battery test - Passed. Scheduled diagnostic testing for 8-22-2022.
8-22-2022: Dealer pulled DTCs P1A10 and P0C78 and performed pin test - Passed.
8-26-2022: Picked up truck. Drove normally.
8-27-2022: My ford customer experience agent called me (on a Saturday). She confirmed that Ford engineering had initiated a hotline with the dealer service tech on 8-22, presumably to walk through the pin testing. She indicated that she did not talk directly with engineering as they are not “customer facing” and that engineering only communicated with dealer service techs.
| TECHNICAL SERVICE BULLETIN Illuminated MIL And/Or Stop Safely Now Message, Low Or Discharged 12V Battery And/Or Various DTCs - Built On Or Before 28-May-2022 | 22-2178 01 August 2022 | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Model:
Issue: Some 2021-2022 Mustang Mach-E vehicles built on or before 28-May-2022 may exhibit an illuminated malfunction indicator lamp (MIL) and/or display a Stop Safely Now message in the instrument panel cluster (IPC) with diagnostic trouble codes (DTCs) P0563, P0ADA, P0ADE, P0AA1, P0AA4, P0AA5, P0AA2, P0D10, P0D0F, and/or P0C78 stored in battery energy control module (BECM) or a low/discharged 12V battery with P0DA8 and/or P1A10 in the secondary onboard diagnostic module-C (SOBDMC). This may be due to the high voltage battery junction box (HVBJB). To correct the condition, follow the Service Procedure to replace the HVBJB and reprogram the BECM. Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria: • 2021-2022 Mustang Mach-E • Built on or before 28-May-2022 • At least one of the following: - DTCs P0563, P0ADA, P0ADE, P0AA1, P0AA4, P0AA5, P0AA2, P0D10, P0D0F, and/or P0C78 in the BECM - A low/discharged 12V battery with a P0DA8 and/or P1A10 in the SOBDMC Parts
Unit of Issue refers to the number of individual pieces included in a service part number package. Piece Quantity refers to the total number of individual pieces required to repair the vehicle. As Needed indicates the amount of the part may vary and/or is not a whole number. Parts can be billed out as non-whole numbers, including less than 1. Parts Parts To Inspect And Replace Only If Necessary
Warranty Status: Eligible under provisions of New Vehicle Limited Warranty (NVLW)/Emissions Warranty/Service Part Warranty (SPW)/Special Service Part (SSP)/Extended Service Plan (ESP) coverage. Limits/policies/prior approvals are not altered by a TSB. NVLW/Emissions Warranty/SPW/SSP/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool. Labor Times
Service Procedure 1. Replace the HVBJB. Refer to Workshop Manual (WSM), Section 414-03A, Removal and installation. 2. Reprogram the BECM to latest software available. The BECM is part of the powertrain coordinated flash. (1). Connect a battery charger to the 12-volt battery. NOTE: To prevent the battery saver mode from activating on the vehicle, verify that the negative cable of the charger is installed on a chassis or engine ground, and not the 12-volt battery negative terminal. Do not plug the vehicle into the high voltage battery charger during programming, this can cause modules to not program correctly. Only use the 12-volt battery charger during programming. 3. Reprogram the PCM using the latest software level of the Ford Diagnosis and Repair System (FDRS) scan tool. 4. Check the availability of software updates on the following modules and update as required:
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