*******HYBRID DEAD BATTERY REPAIR- CABLE LUG REPLACEMENT**********

[Mach 1]

Ok, heres the repair for the hybrid battery cable

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[TedTX]

Have family at home on the lake, think it’s this year Christmas at their place.

 

[Jatrax]

Might want to edit that title. Sure sounds like you repaired the battery, not the wiring harness. At least that was my thought.

 

[BoboysTruck]

Might want to edit that title. Sure sounds like you repaired the battery, not the wiring harness. At least that was my thought.

This

And link too

 

[BoboysTruck]

I googled it.

https://www.ebay.com/itm/373440848108

Or if you prefer Amazon

ANTI-TURN ALUM MECH LUG ONE CONDUCTOR- 250KCMIL-6 (Pack of 1) https://a.co/d/elVJCRc

 

[Mach 1]

Ok, changed, thx for feedback.

Here's my write up on the actual problem/inspect.

https://www.mavericktruckclub.com/forum/threads/hybrid-battery-cable-lug-inspect.20063/

 

[Jatrax]

Thank you! Excellent write up.

 

[Mach 1]

Ted, I am right on the lake, Travis, Colorado River, Lake Buchanan, Inks Lake, etc.

 

[glohworm]

Randy, thanks so much for all your efforts to inform our members here. I live in an old mobile home (1970) and aluminum wiring was a rude awakening for me! Anyway, you've been spot on how aluminum and copper don't like each other.
Just viewed the latest tutorials concerning the harness on Youtube. I was hoping you'd have the chance to make a tutorial yourself. My truck sits dead at my place since 8/26, waiting for Ford to send out a nationwide TSB.

 

[Mach 1]

Worm, its not that bad to DIY.
I have pics and how to. I even told what tools, 15mm, 8mm, 10mm (battery), good light, push pin puller,

https://www.mavericktruckclub.com/forum/threads/hybrid-battery-cable-lug-inspect.20063/

This is inspect, read owners manual about pulling fuse box will need that info.

Today i posted my part i would have used if mine was bad.

https://www.mavericktruckclub.com/f...d-battery-repair-cable-lug-replacement.20263/

If you have any questions pm me if you like

 

[Timothyd]

Ok, heres the repair for the hybrid battery cable fiasco. I have my own repair, now that we have seen so many repair fails, and we understand that the vendor doesnt even know that they are producing defective cables YET!

I use a copper clad lug, oh wait we are working with aluminum cable so there is no copper involved. So no need for copper or clad, cause i have an aluminum lug.
No need for huge crimpers here, just install, torque, wrap with tape, touch of Deox, and wham-o, call it done, rest at night knowing your Mav has a #1 professional repair.
If you are in central Texas, let me know.

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Ha! I have that exact same lug in my pocket right now. I got it after watching a YouTube where the guy, a Ford technician, repaired that crappy, soldered connection to the battery. This wiring harness issue is just lousy terminations. The YouTube I saw is:

Ok, heres the repair for the hybrid battery cable fiasco. I have my own repair, now that we have seen so many repair fails, and we understand that the vendor doesnt even know that they are producing defective cables YET!

I use a copper clad lug, oh wait we are working with aluminum cable so there is no copper involved. So no need for copper or clad, cause i have an aluminum lug.
No need for huge crimpers here, just install, torque, wrap with tape, touch of Deox, and wham-o, call it done, rest at night knowing your Mav has a #1 professional repair.
If you are in central Texas, let me know.

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Ha! I have that very same lug in my pocket. I got it after I saw a YouTube of that connection problem. It's not the harness, it's that shitty soldered cable to plate. Here's some other lugs I've used.

 

[Mach 1]

Tim, have you tried all those, or you going in first and then decide?

 

[Mach 1]

If you use the aluminum block on the left, its all aluminum, then theres no problem with mixing metallurgy. In his first vid, hes like probing around and hits the cable lug and it reads 3v but it doesnt sink in. So he goes home and comes back next day and crimps a big ol copper lug on the aluminum cable. All the other guys approve stating'he crimped the hell out it, it aint coming off'.
They just missed it, and this guy is a Ford tech, and this is what you get at your local dealership.

Hey Tim, you know what you are doing, would you comment on what would fail on a copper lug crimp, and how quickly it would fail?

 

[Wire4money]

Pretty sure the wire is tinned copper and not aluminum.

 

[glohworm]

Pretty sure the wire is tinned copper and not aluminum.

Wow, Tim, if this is true, it kinda changes everything. It makes so much more sense that the harness is stranded tinned copper wire. It always bothered me that Ford would design this hybrid using aluminum. So, apparently a copper lug will do the trick. Go figure.

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