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****REGARDING DEAD HYBRID MAVERICKS ISSUE****

Scupking

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JASmith

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What a great time to buy a new vehicle... All the manufactures trying to cut corners to meet demand with the supply constraints...
True, not a great time to be an auto-enthusiast, but at least car prices are at an all time low and gas is cheap. Oh, wait....
 

Scupking

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True, not a great time to be an auto-enthusiast, but at least car prices are at an all time low and gas is cheap. Oh, wait....
I guess I'm not making the smartest move by trading in a reliable paid off 15 year old suv for a potentially unreliable new truck... Oh well....
 

mamboman777

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Dadmezz

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QS 9000 .Systems
what Are they good for again?
 

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Mach 1

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Scup, you did the right thing, fuel at $4.50g, its returning on your investment right now and for years to come...

Thats the way i see it, for me as well. First year, just some minor teething/growing pains.
 

glider

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I guess I'm not making the smartest move by trading in a reliable paid off 15 year old suv for a potentially unreliable new truck... Oh well....
Having second thoughts too. My current 4runner is reliable. Never left me stranded. Sure like to hear from Ford about this???????
 

LessFrequent

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Having second thoughts too. My current 4runner is reliable. Never left me stranded. Sure like to hear from Ford about this???????
Similar situation here. My 2004 Toyota Tundra Limited 4.7L with <75K miles has never given me a hint of a problem other than had to replace the power steering rack due to leak last year.

Wanted to get something with good gas mileage that wife and I could drive around the country on a National Park tour, but not so sure this Maverick is it. Might just bring along a couple of 5 gallon gas cans under the Tundra BakFlip instead...
 

VAMavOwner

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Clubs
 
Yeah, you could say it does. Although I don't have much of a theory... I've just tried piecing together everyone's story/timeline.
That wire looks exactly like mine. If you take out the fuse box to the right of that, you will see a second nut behind that one (also seen later in this thread). That is where the suspected bad cable is located. Not sure how it does it, but when I jump it, it runs great, switches between electric and hybrid no problem, but as soon as I turn off the ignition switch, it goes dead again.
 

013SamIAm

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It looks like there is an issue with the welds on the battery cable at the Battery Junction Box. It is hidden under the shrink tubing, so if you are having issues, I would start there.

lug1.jpeg


lug4.jpeg


lug3.jpeg


lug2.jpeg
that's exactly what the one we have in the shop looks like! Thank you. You saved our tech hours of frustration! It's fun when the parts guy can walk out and tell them what to look for!
 
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Mach 1

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I am going to change my mind, and say that is some type of electric resistance welding, the 2 bar imprints are electrodes and using resistance creates a weld/solder bond.

Temp, pressure, cleanliness, establishing resistance is key to completing the bond.
 

YOBY

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I am going to change my mind, and say that is some type of electric resistance welding, the 2 bar imprints are electrodes and using resistance creates a weld/solder bond.

Temp, pressure, cleanliness, establishing resistance is key to completing the bond.
Your right. Quick, but stupid to do at a critical connection.
 

OleFordGuy

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Mach 1

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Ok, so does this change our approach for permanent reliable connection, just use an AL clad lug and pressure crimp on to cable?

I can claim this, whatever we come up with is going to be better then this failure!!
 

YOBY

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Ok, so does this change our approach for permanent reliable connection, just use an AL clad lug and pressure crimp on to cable?

I can claim this, whatever we come up with is going to be better then this failure!!
I'm waiting for FORD to decide if they are going to replace the harness. If I hear crickets into October, I will take the connector apart and see what the materials are made of and formulate a plan of attack. I'm not going through the winter with that time bomb.

I know of no Electronic/Electrical Engineer, including myself, that would only attach one side of a power wire to a lug. For any power application, you want as many strands as possible in contact with the lug to gain the best gas seal possible. Pure Stupidity. (10 to 1, somebody at Ford received an award or bonus for that time saving idea)
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