Tracking DEAD HYBRID Mavericks Reported Dealer Solutions / Fixes ...

[uga]

Or fix it correcty myself. I have seen some of the repairs that are being done for this, theres no consistant repair, theres like 6 different repairs.
The only way these should be repaired is with a new harness.
I have seen copper lugs being used, which is a huge red flag.

I dont like dealerships, the ones here, all i get is we cant replicate the problem. I still have my 2018 F150, i complained about the brakes, dealer said brakes are fine.
I had them note it against my VIN.
Theres a class action lawsuit out on 2015-2018 F150, guess what for? Brakes! So sign me up.

There are more and more class action law suits because we as customers get pushed aside and dont have any power to get work done.

I believe i saw a class action law suit the other day for the Mavs, i dont blame these customers.

Its great that you have the technical knowhow. However, as you know, there is risk in doing something this complex. The average person should find a credible dealer and get all repairs documented. If something goes wrong in the future you will have recourse and your warranty.

Thanks for your contribution and pics!

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[Mach 1]

Uga thx for discussion, i wish it was that simple and easy, there are some horror stories here as you know. Cars in shop for over a month, people cant get answers, easy, straight forward repair.
Theres an alternative, thats why these websites exist. To spread knowledge, which is power in the hands of the consumer.

This repair is one notch up from installing a side battery terminal on a chevrolet. We used to do these all the time.

The path has been laid down in front of us, the guess work is done.

I dont know if the dealership can void your warranty because we repaired something correctly that they couldnt in the first place.
Plus, how would they know we fixed it, i sure aint going to run up to them and tell the dealership, hey look i modded my cable!

Sometimes i get a little confused, cause i got this gift, but it is not a gift its self educated. I guess i think everyone can do what i can. This society has become a disposable society. We dont fix it, we get a new one to replace the old one.

Uga, this is not directed at you, i appreciate conversating with all.

 

[Sliphorn]

Uga thx for discussion, i wish it was that simple and easy, there are some horror stories here as you know. Cars in shop for over a month, people cant get answers, easy, straight forward repair.
Theres an alternative, thats why these websites exist. To spread knowledge, which is power in the hands of the consumer.

This repair is one notch up from installing a side battery terminal on a chevrolet. We used to do these all the time.

The path has been laid down in front of us, the guess work is done.

I dont know if the dealership can void your warranty because we repaired something correctly that they couldnt in the first place.
Plus, how would they know we fixed it, i sure aint going to run up to them and tell the dealership, hey look i modded my cable!

Sometimes i get a little confused, cause i got this gift, but it is not a gift its self educated. I guess i think everyone can do what i can. This society has become a disposable society. We dont fix it, we get a new one to replace the old one.

Uga, this is not directed at you, i appreciate conversating with all.

..
I appreciate what you say. Being informed, self educated, (aren't we all), is great. But many of us, myself included, may have the skills and know how but are unable to do so because of aging hands that do not work like they once did. I also appreciate your willingness to do the work for someone else if they come to you for the actual fix. Top notch!
..

 

[Chris_G]

..
I appreciate what you say. Being informed, self educated, (aren't we all), is great. But many of us, myself included, may have the skills and know how but are unable to do so because of aging hands that do not work like they once did. I also appreciate your willingness to do the work for someone else if they come to you for the actual fix. Top notch!
..

Well said!

 

[skinnyboy]

Ford Boss Me (master mechanic on youtube) posted a video tonight on his diagnostic process on repairing this issue. He muttered A LOT under his breath about the extent of dirt and corrosion in the junction box, implying poor materials along the way and speculating that this one sat a long time in the Mexican desert wating to be picked up.

IDK, I'll bet it turns out to be the cable termination at fault, not some surface corrosion on the bus. Curious to see how this gets "fixed" on the next video.

Cheers.

 

[Uncle Ed]

IDK, I'll bet it turns out to be the cable termination at fault, not some surface corrosion on the bus. Curious to see how this gets "fixed" on the next video.

Cheers.

Don't forget to register a complaint with the National Highway Traffic Safety Administration, I saw last week only 50+ complaints on the Maverick , of which 25 were electrical.

 

[Mach 1]

Thanks guys for kind words, support. I would almost extend the invitation to any member. I have sponsored meetings at my shop, i work on all the neighbors vehicles, welding, lawnmowers.
I learned early in life as a teen, i was in the Coast Guard and offered help or a rescue to most people.

Slip, i havent divulged, i am handicaped, blew my back out, permanent partial nerve paralysis. I m 66, hands and sights are leaving. I wont let it stop me, it did slow me down alot!

Skinny, i think you called it right, heck we even saw in the vid where he only had 3v coming from battery. The fuse that was blown was kinda weird, plus replacing it has to be soldered in. He kinda got side tracked by the fuse box. I just took all the members posts and figured out which connection was the most obvious and jumped in head first.

 

[flashfearless]

IDK, I'll bet it turns out to be the cable termination at fault, not some surface corrosion on the bus. Curious to see how this gets "fixed" on the next video.

Cheers.

He posted part two tonight. He wound up making a custom copper cable for that post, and demonstrated how the material around that fuse is so heat resistant that solder doesn't stick to it.

 

[Mach 1]

Yeah, the reason the cable wouldnt solder is because its next to impossible to solder aluminum, you have to have special solder, special flux, and very controlled heat.

That right there should have told him not to mix copper and aluminum.

Thats a big fail.

 

[flashfearless]

He also just revealed in the comments that there were two manufacturers for the harness and Ford is "trying to get to the bottom of it". Implying that one of the two manufacturers is the source of the issue.

 

[Zotman]

Mach 1, thanks much for your input. If you don't mind telling us, I think we'd all appreciate your opinion based on your knowledge of what might be expected of the copper/aluminum repair, i.e., how long it might last or what the failure would look like. Just trying to get an idea of what lies down the road. Regardless, your valuable contributions are much appreciated.

 

[Mach 1]

Zot, thx for valuing my knowledge, theres other members here, we are working with as well. I guess i should have expressed, there are other NON-FORD, people/members working on this, making great strides.
Observations, there is NO STANDARD repair being done on the hybrid Mav. Its up to the dealers to do whatever repair they seem fit.
It doesnt surprise me that the harness maker does not even know theres a QC issue! I saw and posted this a couple days ago, that the vendor doesnt know he has a problem.

So Mav owners this is bad news, from the inception of the Mav hybrid until now can possibly be defective.

 

[Mach 1]

Heres the killer, copper on aluminum will get u out the door, fixed, but for how long?
Thats a great question. Heres more facts, the metals contract/expand at different rates, so the loosening of the crimped joint is Inevitable.

The dissimilar metals heat/corrode at different rates, look up galvanic corrosion, good reading.

IEEE code for aluminum wiring, is dont use it, if you have to join metals you have to follow strict guidelines being AL/CU clad or AL/CUR. This is where Deox comes into play, you want to isolate the joint to prevent OX from exposure to dissimilar metals. Back to galvanic corrosion.

What spec does automotive use for wiring? They have to account for dissimilar metals. When heavy duty computer rich vehicles, where clean/stable voltage is required.
Theres not that heavy flow of amperage charging the 12v battery. However the 12v wiring is for the command/control processor heavy feed. We could see some wacky stuff happen.

 

[Mach 1]

Of course failure is also dependent on environmental, a high humidity climate would show a faster decent.
Operation of the vehicle is going to be important as well.
Depending on it getting sealed..Deox, could/would postpone it.

I worked with marine engines in my early career.
That salt water eat the heck out of sacrificial zincs, and if they were gone, i have seen huge holes in real thick metal. Brass is metal of choice in marine applications. We had zincs in our cooling water(water heaters), if they were not changed on regular schedule, GC went after cylinder liners, exhaust manifolds(heat).

Bottom line, i know enough(not an expert in failure analysis), i was on the other end trying to reduce the effects of.
I would not accept the repair on my vehicle.
I have reached out to Ford to conversate with them about this situation, i need a phone number if anyone has one, please.
I have been in mine, and an inspection revealed it is attached quite well, i got lucky. I even volunteered to help others steer their way through this nitemare that could take a very bad turn.

 

[Hoagus]

That right there should have told him not to mix copper and aluminum.

Consensus in other threads is to use a copper clad crimp-on lug.

Do you disagree with that? If so, why?

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