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

[Wire4money]

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.

I would imagine an aluminum wire would probably start breaking strands. It is nowhere as durable as copper.

Sponsored

 

[Ducky2022]

Pretty sure the wire is tinned copper and not aluminum.

Someone needs to scrap the wire for tin coating! Everyone is assuming aluminum because of the way it looks.

 

[Miskomd]

I used this plus anti-ox plus heat shrink on mine, was pretty easy. Hoping it holds up long term. Have to take off the fuse box to access. Worked well with the somewhat flat wire end (due to leftover solder on the failed joint- flat connected to the factory lug)

Burndy KPA25 Tin Plated Copper Terminal Lug 4 AWG-1/0 AWG SCRULUG
https://www.walmart.com/ip/111682267

fyi the wire is definitely aluminum, not tinned copper

 

[jdiaz]

Its interesting that such a large cable is grounded only thru the threads of the attachment screw. That plated lug is touching on paint, and not conducting anything to the body.....the energy is going thru the screw head and threads to the connection point, and that is barely any surface area at all, unless I am interpreting this photo incorrectly.
https://www.mavericktruckclub.com/forum/attachments/20220911_195932-jpg.66404/

It makes me think you could use one of these to fulfill the ground connection, and get just as much current carrying capability. Might be worth throwing one of these in the glovebox in case a repair is needed on the road.

 

[Miskomd]

Its interesting that such a large cable is grounded only thru the threads of the attachment screw. That plated lug is touching on paint, and not conducting anything to the body.....the energy is going thru the screw head and threads to the connection point, and that is barely any surface area at all, unless I am interpreting this photo incorrectly.
https://www.mavericktruckclub.com/forum/attachments/20220911_195932-jpg.66404/

It makes me think you could use one of these to fulfill the ground connection, and get just as much current carrying capability. Might be worth throwing one of these in the glovebox in case a repair is needed on the road.

You’re interpreting the photo wrong, it terminates to a post connecting to fuse box. It’s also the +, not -

 

[Mach 1]

Got 2 theories about it at least, long length cable=lots of weight, aluminum is how much lighter, gauge of wire is huge, like at least 2/0 but probably more like 4/0. I use a 250 lug size.

Other ideas, battery load is maximum recharge, which with a small battery (390ah)is miniscule,
The negative cable is copper or tinned.

That sheet metal piece is very important job, i refer to it as the buss bar. The cables have a large area for such a small load, its the size of the lug flat spot, plus the stud. That size is usually what they spec for something twice the load.

 

[Mymaverick2021]

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.

View attachment 66883

View attachment 66884

View attachment 66885

View attachment 66886

Yea DYI IT AND Void your warranty

 

[Mach 1]

My, they cant void your warranty without a reason, plus this approved repair is 14 times better then what their techs are doing using copper lug.
On top of that i wouldnt mention it to anyone, do you think when you take it in for work, that the service writer is going to run over to the Mav pop the hood and check it?

Plus their tech did a supposely temporarily repair, and we cant? I dont understand your logic?

Sponsored