Shift SYS Fault - Service Required (Hybrid CVT)

[23grayXLT84]

UPDATE
just heard from the ford people, wire harness is back ordered until November 15th. WOW, that will be down 4 months. this is crazy. My truck was down this time last year for 2 months for the same thing.

seems like a harness should be repairable at least temporarily....

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[Tech Tye]

I asked and they wouldn’t do it. I am asking for a extended warranty.

 

[Maverick_Innovation_Designs]

Just had the same issue error code, waiting a few hours to see if the issue is able to resolve. I confirmed that it was also built 3/22, which aligns with a number of the people on this thread. For reference, I've put on about 25k miles and this issue happened while parked in the garage.

I'm going to file a NHTSA report because it does seem like an unusual issue common to specific build dates.

 

[Tech Tye]

First time it happened was last year this same time . They put transmission in and 2 hybrid control modules. That was around 16,500. This time at 34,000 it did it again. Now it’s a wire harness with corroded pins at the 40 pin connector located in the drivers front wheel well. I do wash my truck daily . Not sure that’s what did it, however that’s a dumb place to put a module to keep it dry. They have 1 harness and the other is still on back order with a ship date of 11/8/24, so down 3 months again!

 

[Maverick_Innovation_Designs]

I’m leaning towards a faulty wire harness. I’m sure some 8 year old prob crimped the pins wrong. I was going to try some zip ties and put tension on the harness where it goes into the module. One of the other post stated the tech was able to duplicate the issue by wiggle test and was able to watch it on the service laptop. This sounds like bad crimps or the pin/socket not mating correctly.

One of the initial posts had a loose pin found on C199A-8. Looking closer, it also seems like Ford went with silver or tin pin contacts, which don't have the same corrosion resistance as the gold. I also didn't find any dielectric grease along the HV busbars or connectors... which they otherwise need to limit corrosion (long-term). So I'd say it's a combination of them going fast/loose and cutting cost.

After the warranty, I'm likely going to go through the truck and put dielectric grease everywhere it was supposed to go in the first place.

 

[Tech Tye]

I gave the ford tech a large tube of dielectric grease to put on when it does get here. Driving a ford escape now while I wait

 

[Maverick_Innovation_Designs]

First time it happened was last year this same time . They put transmission in and 2 hybrid control modules. That was around 16,500. This time at 34,000 it did it again. Now it’s a wire harness with corroded pins at the 40 pin connector located in the drivers front wheel well. I do wash my truck daily . Not sure that’s what did it, however that’s a dumb place to put a module to keep it dry. They have 1 harness and the other is still on back order with a ship date of 11/8/24, so down 3 months again!

Do you know the PNs for the wire harnesses by chance?

 

[Tech Tye]

Not yet, I know they are 40 pin latch style. I think there is a BCM in the fend well

 

[Maverick_Innovation_Designs]

I gave the ford tech a large tube of dielectric grease to put on when it does get here. Driving a ford escape now while I wait

Definitely have them do it at the main fuse box/busbar if they will (underneath the main fusebox). It seems like some of the 12v issues stem from them putting two plated busbars on top of each other during different stages of production... with varying levels of debris caught in-between. That's a nightmare for corrosion down the road.

 

[Maverick_Innovation_Designs]

Not yet, I know they are 40 pin latch style. I think there is a BCM in the fend well

All good, I'll do a reverse a lookup with the electrical diagrams. I'm assuming the two you're talking about are the male/female parts of the wiring harness? Or two different wiring harnesses entirely?

 

[Maverick_Innovation_Designs]

Not yet, I know they are 40 pin latch style. I think there is a BCM in the fend well

I believe it's the SOBDCM (secondary on-board diagnostic BCM). Wiring harness is the one that connects the SOBDCM to the HF45 Transmission, also known as the Battery Cable Harness (NZ6Z-14305-B). Does that look right to you?

 

[Tech Tye]

Just left ford dealer and he showed me the issue , it’s 2 large plugs that plug into each other. It’s on the very front left corner. He got to it from under the truck. I could see a module on the back side of these. He said this is a common issue on all models.

 

[Maverick_Innovation_Designs]

It hasn't happened since but I took the truck to the shop anyways. They saw the code and diagnosed it as an issue with the IPC switch panel (NZ6Z-11500-AA)... I don't know enough to disagree but that certainly seems strange.

@Tech Tye I'm planning on waiting until warranty is over then going through the connectors and adding dielectric grease as a preventative measure just to be safe.

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