The Dreaded Dead Hybrid

[BoboysTruck]

2022 XLT with 130K plus miles. I do have a 5Yr/150k miles Extended Warranty.

It happened yesterday for the first time. My wife went to get some groceries about a mile from the house. Got back in the Mav and nothing. It had to be jump started to get it home. It is sitting dead in the driveway right now.
The 12V battery was replaced in December and measures 12.8V at the posts. Under the hood however, I'm only getting 3.8V
Before I take it to the dealer, would like some input from folks who have had this problem. Was the issue the cable?
What was the fix?

TIA.

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[icegradner]

Did you get the 12v battery cable replaced under the customer satisfaction program Ford offered a few years ago? It would have been free, but that program ended. If that is the problem, hopefully the warranty covers it, it’s not cheap.

If it’s not the charging cable, it could be the AC issue, someome here will likely have a link for that.

If it’s not due to either of those then, there is no fix sadly. You could disable Fordpass and pull fuse 11 to reduce the system trying to send info over the cell phone network to Ford.

 

[TheSEARCH]

Check again If it is really 12.8 at battery posts. BUT only 3.8 at under hood jump points it sounds like the battery cable thing the 2022's had. Ford had to replace a bunch of cables on the 2022 models. But was fixed by 2023 model,

 

[BoboysTruck]

Unfortunately, I did not get the cable replaced. I was not having the problem. I will pull the fuse later when I get home.
I remember some guys doing a DIY fix with the cable but can't find it. Hopefully, someone can link me to that. In the meantime, will jump starting the truck be a temporary fix for now? Will it stay running and not die in the middle of the road?

 

[BlueSpec1]

Unfortunately, I did not get the cable replaced. I was not having the problem. I will pull the fuse later when I get home.
I remember some guys doing a DIY fix with the cable but can't find it. Hopefully, someone can link me to that. In the meantime, will jump starting the truck be a temporary fix for now? Will it stay running and not die in the middle of the road?

One of the DIY Fix threads:
https://www.mavericktruckclub.com/f...epair-cable-lug-replacement.20263/post-382502

 

[HeyBales]

Unfortunately, I did not get the cable replaced. I was not having the problem. I will pull the fuse later when I get home.
I remember some guys doing a DIY fix with the cable but can't find it. Hopefully, someone can link me to that. In the meantime, will jump starting the truck be a temporary fix for now? Will it stay running and not die in the middle of the road?

Modem being turned on for a blip every hour while it sits unused ain't your problem - don't bother with the fuse since your voltage appears to show it's not a concern now.

If those voltage readings are correct, it's the issue of getting the rather minor amps up to where they are needed to allow the truck to start.

There were also some threads showing pic's of the areas that had the issue - so you could confirm that cable issue.

Because it could be similar but different. But that sounds like a driving issue too - while the battery is only being charged once it's On/Ready - I could see the system freaking out if it appears unseen after some driving - and only giving you some limp mode to get pulled over.

Then again - if it was never required to be a recall, maybe it doesn't do limp or shutoff in middle of road - that usually causes a recall for safety.

 

[icegradner]

Unfortunately, I did not get the cable replaced. I was not having the problem.

That's unfortunate. My dealership recommended I do it, even though I never had the truck fail to start. They also replaced one of the big fuses under the hood, which at the time was a known issue as well. I'd have to dig out my service notes, but some of them were cracking or were faulty from the factory.

 

[jeffrol48197]

22B39 was the program, if you want to check it out and let them know - I checked my paperwork...I just googled it and can see the whole program through NHTSA

 

[skinnyboy]

If you can find someone you trust to do a decent job crimping a new end on the positive cable that would be my choice. The Ford cable "overlay" repair was a bit of a bodge (at my dealer anyway), I wouldn't pay an arm and a leg to have it done.

Cheers.

 

[BoboysTruck]

That's unfortunate. My dealership recommended I do it, even though I never had the truck fail to start. They also replaced one of the big fuses under the hood, which at the time was a known issue as well. I'd have to dig out my service notes, but some of them were cracking or were faulty from the factory.

Yeah, I wish I had done this.

 

[BoboysTruck]

22B39 was the program, if you want to check it out and let them know - I checked my paperwork...I just googled it and can see the whole program through NHTSA

I saw this but it seems I am SOL as it expired June of last year.

 

[BoboysTruck]

It seems my problem is not the battery cable because of I disconnect the cable from the post, I get battery voltage. As soon as I bolt it back down to the post voltage drops down.

 

[BoboysTruck]

I self jumped it by connecting a jumper cable from the battery to the jump post and started it. She started with no problem but the CEL is on and this is what I pulled.
You guys know where that relay is located?

 

[BlueSpec1]

It seems my problem is not the battery cable because of I disconnect the cable from the post, I get battery voltage. As soon as I bolt it back down to the post voltage drops down.

The PCM Power Relay is inside the BJB on a printed circuit board.
https://www.carparts.com/blog/p068a-code-ecm-pcm-power-relay-de-energized-performance-too-early/

The 12V drops down when you connect the battery cable onto the high current battery junction box without the BJB(Fuses, Relays) plugged in, leaves the DC/DC, PSCM, BCM able to draw down the 12V.

 

[BoboysTruck]

I checked it some more and here are additional troubleshooting information to add.
I cleaned all the contacts and plates in the battery junction box. All the mega fuses are good. If and when I take this to the dealer, they'll know someone messed with it because I broke a couple of clips and had to use zip ties.
Anyway, I get battery voltage to the cable, even after bolting to the post and attaching the fuse box. As soon as I attach either of the big connectors to the fuse box, the voltage drops.
I disconnected and unbolted everything again to replicate the condition and same thing.
This scares me because this repair could/will be pricy. I'm gonna have to read up on the extended warranty terms and conditions.

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