Remote features disabled, Water leaking from dash, Dash rattles

[23grayXLT84]

My Maverick is in the shop now going on 6 weeks and they are trying to find the leak. Window was good but now they are saying they have to replace the heater fan because it is bad from water. Dash is being pulled this week and still looking for the cause. Inside of my truck is moldy so carpet is being replaced too. I have a 2023 with 12,000 miles on it. Good luck

It's the little cover underneath the cowl . The cover covers the HVAC air intake
.common issue assuming water is in your passenger foot well. When I say common I mean 9/10 it's that.

Cover is easily mis installed.

Easy to test. Remove HVAC filter, look inside with a flash light while someone pours water on the windshield etc. you see water going in....

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[Brumbach]

****UPDATE*******
I wanted to give updates for these issues. Today i was getting ready to take my Maverick back to the dealership to get worked on. It was under 10 degrees last night. I notice when i was scraping the frost off the windshield there was frost on the inside of the windshield also. When i got to the dealership a tech was getting ready to take my Maverick from the sally port and told me there was ice under the floor mats, in the carpet. I guess the water that's been coming in froze solid. Updates to come....

 

[Brumbach]

*****UPDATE******
Dealership called and said 12volt battery is bad. They are going to install the shim kit for the dash rattle tsb listed in above comments, and the leak is coming from the hvac intake under the cowl as listed above. They will try to dry out the water intrusion. Its interesting that when it was in a month ago for the rattle and battery issue they said the battery was fine and the tsb did not pertain to my dash rattle issue, he said the dash had to come out. Parts are being ordered and i will update when i get the vehicle back.

 

[rightmuch]

Did they fix the dash rattle? I took mine in on Monday and they put the foam blocks in per the TSB. Didn’t completely eliminate it, but it’s infinitely better. Tolerable.

 

[Brumbach]

Did they fix the dash rattle? I took mine in on Monday and they put the foam blocks in per the TSB. Didn’t completely eliminate it, but it’s infinitely better. Tolerable.

My truck is still at the dealership. As far as the dash rattle they are ordering the tsb kit. When i took it in in Novernber they said the Tsb was not the issue. They were gonna pull the dash. Now there saying its the tsb. Also in November they said the electrical problem was fixed by resetting the BMS. Now the battery is bad. I also have water coming into the Hvac system, a lot, frost on the inside of the windshield and ice on the carpets and this electrical problem. I will update this thread when i get it back. They are saying the water intrusion is coming in thru the cowl. I would recommend every one check their cabin air filter after rain to catch this before it gets as bad as mine. They are also waiting for parts to fix the cowl. Stay tuned,,hahaha

 

[HeyBales]

My truck is still at the dealership. As far as the dash rattle they are ordering the tsb kit. When i took it in in Novernber they said the Tsb was not the issue. They were gonna pull the dash. Now there saying its the tsb. Also in November they said the electrical problem was fixed by resetting the BMS. Now the battery is bad. I also have water coming into the Hvac system, a lot, frost on the inside of the windshield and ice on the carpets and this electrical problem. I will update this thread when i get it back. They are saying the water intrusion is coming in thru the cowl. I would recommend every one check their cabin air filter after rain to catch this before it gets as bad as mine. They are also waiting for parts to fix the cowl. Stay tuned,,hahaha

I noticed in your comments regarding the BMS reset - nothing about them charging the battery, and letting it sit locked overnight.
Doing the BMS reset on already low battery - terrible bone-headed idea - they have procedures that state full charge 1st.
But at least you got your 1st warranty battery out of their mistake.

The other items not being realized were known possible issues - concerning.

I wouldn't trust this dealership at all.
How long out of warranty will stuff show up due to whole dash being taken out, or water logged items showing rust and having issues?

 

[Brumbach]

Agreed. Ford from top to bottom, From Dearborn to Hermosillo to Quakertown has failed to deliver.

 

[Brumbach]

My Maverick has 3000 miles on it. I have been brand loyal since 1992. This is my last Ford.

 

[rightmuch]

Agreed. Ford from top to bottom, From Dearborn to Hermosillo to Quakertown has failed to deliver.

Sorry you’ve had so much trouble. I feel fortunate because mine was one of the first ‘22 Mavs to be delivered. Had to deal with the recalls, but otherwise it’s been a great vehicle.

 

[icegradner]

My Maverick has 3000 miles on it. I have been brand loyal since 1992. This is my last Ford.

Cannot blame you for that, if I had that happen to one of my vehicles I would do the same thing. Having poor service from the dealership is just the icing on the cake I'm sure.

 

[S Dundee]

The Mavericks on balance are really good trucks, with crazy good fuel economy on the Hybrid. What I would say is that there are a) very many recalls primarily software and b) a small number of recurring suppler/manufacturing defects on the Maverick. Some of the Ford dealerships are fairly impotent to fix many of the issues, and frankly the user community on Maverick Truck Club is a lot better informed. Around me, out of 4 Ford dealers only 1 has a good service department which also supports mobile service for the recalls.

The water leak you experienced is probably the seal between the cowl panel and the cabin filter. This is a well known problem on this forum (with main symptom that you have a water leak on the passenger side and the cabin filter is saturated with water) and one that is easily corrected by the dealer. Unfortunately, many of the dealers aren't as well informed. See https://www.mavericktruckclub.com/forum/threads/water-leak-into-cabin-from-cowl.46722/
or https://www.mavericktruckclub.com/forum/threads/water-leak-intrusion-into-cabin-update.44412/

A lot of Hybrid owners, including myself, have replaced the wet cell 12v battery under the rear seat with AGM on our own dime to address the deep sleep mode. For me, even in cold weather the AGM battery has performed great. If you get size H4, it drops right in with no modifications. So yes Ford should have paid for that, but for $150 it was worth it to me to be able to enjoy the truck without all the deep sleep mode alarms.

Even though the truck is under warranty, the degree to which you can do your own diagnosis before engaging the dealer is a huge benefit. This is probably true for lots of brands and models, not just the Ford Maverick.

On a modern car, the dash is a complete assembly (normally subcontracted) and installed at the factory as one unit with all electronics and wiring already attached. It is a mystery why some do and some don't rattle, although probably the clearance between the windshield and the dash is the issue. There are also other solutions that have been posted on this forum for the rattling.

Best wishes to U.

 

[Brumbach]

*****UPDATE*****
Just picked up my Maverick. Results as follows:

#1-Dash rattle was verified and TSB 24-2317 was installed.

#2 Water coming into passenger floor at glove box verified. HVAC air inlet screen seal deformed. Replace #18D395 inlet screen and dried carpets.

#3 Battery saver mode on. Battery failure #10655. installed GRX tester and failed. DTC code 5U7 R4JX aces code F86ER. Replace battery and reset BMS. Part# BXT*99RT4*A

***Try to talk to the guy working on the vehicle if you can. A service advisor is a sales position and may not have a working knowledge of what was done or what was wrong. ***

 

[Brumbach]

******* update ********
As the weather started getting warmer the dash rattles and clunks are worse than ever. My Maverick is back at the dealer. They said they know what's wrong this time and there gonna fix it this time. They need it for a week and they are pulling the dash. They discontinued there loaner program and do not rent cars. So my car is down again and now I have loss of transportation . I bought a new vehicle to avoid these issues. When it comes back its going to be sold. This is the worst new vehicle I ever bought. Ford and their dealers are thieves.

 

[notfast]

They probably just didn't know how to fix it.

The tech gets one hour of diagnostic time. Unless there is a TSB or something obviously broken, it's a crapshoot. If they think they are onto something, they need to get additional diagnostic time approved by corporate.

It's easier to say "unable to replicate" but it's also not good to have a high returner rate (after all, Ford corporate is paying for those diagnostic hours if you keep coming back), so there is some incentive to try.

Busted heater core. When the temp drops the cabin car heater turned on to warm the cabin. The core ruptured causing fluid in the dash. This happened to me in a different car.

Sounds like an exterior water leak. Coolant smells sweet and the heater core will always have a small amount of coolant circulating to prevent blockages.

Such a lack of urgency from them. Then i find out the service writer over seeing my issue no longer works there and no one knows whats going on with my truck. They want big money for these vehicles but have amnesia when there is is an issue.

Not making excuses for them, but they sound like they are understaffed. Whether that is intentional because management wants to keep the labor costs down, or unintentional because they can't find anyone willing to spin wrenches is harder to determine.

It's a balancing act as well. Mechanics want to be busy since they get paid flag hours. If the dealership has no work, they quite literally aren't being paid, so they'll pack up and find a busier shop. But if it's so busy that the work is backing up, you'll make the customers upset with long wait times and comebacks.

How long out of warranty will stuff show up due to whole dash being taken out, or water logged items showing rust and having issues?

The whole dash had to be taken out of my Honda HR-V because the blend door was stuck. I think I got pretty lucky because the fitment of the dash was better after it was reinstalled at the dealership than when I bought it with 9 miles on the odometer. I had an occasional, faint rattle, but other than that, no issues for the next several years until I sold the car.

When it comes back its going to be sold. This is the worst new vehicle I ever bought. Ford and their dealers are thieves.

I think that's your best option at this point. Just keep in mind that any automaker will have occasional flaws, so there's a chance that the next vehicle you get will have its own quirks and issues.

If you want guaranteed loaners, generally better service, and free sandwiches in the waiting area, I suggest you look for a "luxury" brand. Amenities like dealership loaners are a courtesy that are not always reimbursed by the manufacturer to the dealership, so sometimes dealerships or dealership chains will offer loaners on their own and set their own terms.

 

[Brumbach]

The tech gets one hour of diagnostic time. Unless there is a TSB or something obviously broken, it's a crapshoot. If they think they are onto something, they need to get additional diagnostic time approved by corporate.

It's easier to say "unable to replicate" but it's also not good to have a high returner rate (after all, Ford corporate is paying for those diagnostic hours if you keep coming back), so there is some incentive to try.



Sounds like an exterior water leak. Coolant smells sweet and the heater core will always have a small amount of coolant circulating to prevent blockages.



Not making excuses for them, but they sound like they are understaffed. Whether that is intentional because management wants to keep the labor costs down, or unintentional because they can't find anyone willing to spin wrenches is harder to determine.

It's a balancing act as well. Mechanics want to be busy since they get paid flag hours. If the dealership has no work, they quite literally aren't being paid, so they'll pack up and find a busier shop. But if it's so busy that the work is backing up, you'll make the customers upset with long wait times and comebacks.



The whole dash had to be taken out of my Honda HR-V because the blend door was stuck. I think I got pretty lucky because the fitment of the dash was better after it was reinstalled at the dealership than when I bought it with 9 miles on the odometer. I had an occasional, faint rattle, but other than that, no issues for the next several years until I sold the car.



I think that's your best option at this point. Just keep in mind that any automaker will have occasional flaws, so there's a chance that the next vehicle you get will have its own quirks and issues.

If you want guaranteed loaners, generally better service, and free sandwiches in the waiting area, I suggest you look for a "luxury" brand. Amenities like dealership loaners are a courtesy that are not always reimbursed by the manufacturer to the dealership, so sometimes dealerships or dealership chains will offer loaners on their own and set their own terms.

When offering free loaners is used as a sales tool the dealership needs to follow thru. If your going to phase it out start with the sales department not offering it. Let me guess the dealerships are broke again.

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