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

[Mach 1]

Yeah, I thought i wanted the replacement harness as well, however if they have to tear truck apart, i dont think so..

I guess wait and see, but be prepped as well in case.

Did i tell you ? I love my Mav.

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[Milous]

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.

So is the bad cable in question located BEHIND the cable end that has the black plastic box covering it?

 

[Gullzway]

So is the bad cable in question located BEHIND the cable end that has the black plastic box covering it?

Check the picture on the first post of this thread. Connection with loose cable is circled in blue.

 

[Milous]

Check the picture on the first post of this thread. Connection with loose cable is circled in blue.

That's the one under the black cap. Awhile back someone mentioned it might be the cable behind that one so wanted to double-check.

 

[Mach 1]

Might be worth it to check all those connections and cable lugs. I havent checked mine, however the nut/stud setup might be worth ptting a socket on..

Just be forewarned that all these connections are 12v positive or HOT!

 

[OleFordGuy]

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)

Yep this design flaw on such a critical component is insane. We see the post of owners stranded in middle of highway with this issue, its sad to write this but someone's gonna get hurt or killed because of it and Ford will have the next Pinto nightmare on their hands. That cable/harness needs re-engineered and replaced on all the hybrids IMO.

 

[huunvubu]

Yep this design flaw on such a critical component is insane.

It is not a Design Flaw as when it is manufactured properly it works as expected.

It is a manufacturing defect that should have been found by testing and/or inspection.

 

[OleFordGuy]

It is not a Design Flaw as when it is manufactured properly it works as expected.

It is a manufacturing defect that should have been found by testing and/or inspection.

Ok however it should be properly labeled/referred to, but I still think they all need to be permanently fixed before something bad happens IMO

 

[Mach 1]

To reiterate, Ford doesnt manufacture most of its wiring harnesses. Its failed/bad quality/failed QC from one of its vendors.

Its very tough to tell if its bad design or failed vendor work, it does appear the harness manufacturer had bad workmanship.

It could have been caught after manufacture with a simple pull test, one would think if its a critical manufacturing operation, they would have had paid better attention, with more stringent control.

 

[Mach 1]

But what do i know?

 

[MAVRICK]

So is the bad cable in question located BEHIND the cable end that has the black plastic box covering it?

Connector C1617E-1

Diagrams from Ford Escape HYBRID

 

[inthecabin]

But what do i know?

That’s only for you to answer…

 

[kenswebdesign]

Yeah, I thought i wanted the replacement harness as well, however if they have to tear truck apart, i dont think so..

I guess wait and see, but be prepped as well in case.

Did i tell you ? I love my Mav.

You don't even WANT a new harness... it might just have the same problem.... there is nothing wrong with the harness... it's just the connector lug on the end.... so remove that lousy one and put on a new crimp on lug and be done with it. That's what my dealer is doing.

 

[Mach 1]

U r right.. I don't want a new harness, whatever is wrong, I will repair myself.

Its what everyone else is going to do with their Mavericks, there's a second thought going on around here that proposes that if 1 joint is effected, why wouldn't their be others on the harness that are effected as well? Usually if your process deviates from normal, it will continue to deviate until something steps in and recognizes and changes the process to get it back under control.

 

[Mach 1]

Then there's the repair that needs to be addressed, there's a possibility that the cable in manufactured of AL( thats what the picture seems to show, although I can't be sure until I get one in hand).

If that cable is AL, then the repair has to be different then 'just put a lug on it and be done with it'.

A CU lug should not be used in this repair, if you put CU on an AL cable you are setting up for failure, its not code approved for an electrical connection, beside the fact and computer will become very unreliable and I believe there will be a large amount of resistance at that connection which equates to heat and etc.

If a repair is done at that connection, it is absolutely CRITICAL that who ever does the repair knows exactly, things like electric code and basic metallurgy.

I don't trust a dealer to do this type of repair on my vehicle with my safety at stake. We are not repairing lawnmowers here, we are repairing a very sofistacated automobile that is very heavily loaded with 10s (if not 100s)of computers communicating with each other with very stringent requirements of electronic connectivity.

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