Truck is Dead - No Power - Hybrid Model

[joeman304]

Just got an update via text on my Maverick:

UPDATE: The technician has completed the no start concern repair and verified VERIFIED CUSTOMER CONCERN VEHICLE WOULD NOT CRANK TESTED VEHICLE BATTERY PASSED CONDITION TEST. CHECKED FOR POWER AT BREAKER JUNCTION BOX, NO POWER 0 VOLTS AT PIN 1 ON C1617E. VISUAL INSPECTION FOUND EYELET CAME APART FROM CIRCUIT SDC02 PER SERVICE MANAGER C.M INSTALLED LOCALLY ACQUIRED EYELET CRIMPED AND RE INSTALLED EYELET, VEHICLE STARTS PROPERLY AT THIS TIME.

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[Maverick2023]

Just got an update via text on my Maverick:

UPDATE: The technician has completed the no start concern repair and verified VERIFIED CUSTOMER CONCERN VEHICLE WOULD NOT CRANK TESTED VEHICLE BATTERY PASSED CONDITION TEST. CHECKED FOR POWER AT BREAKER JUNCTION BOX, NO POWER 0 VOLTS AT PIN 1 ON C1617E. VISUAL INSPECTION FOUND EYELET CAME APART FROM CIRCUIT SDC02 PER SERVICE MANAGER C.M INSTALLED LOCALLY ACQUIRED EYELET CRIMPED AND RE INSTALLED EYELET, VEHICLE STARTS PROPERLY AT THIS TIME.

looks like quality control was neglected at the assembly line.

 

[Gullzway]

Just got an update via text on my Maverick:

UPDATE: The technician has completed the no start concern repair and verified VERIFIED CUSTOMER CONCERN VEHICLE WOULD NOT CRANK TESTED VEHICLE BATTERY PASSED CONDITION TEST. CHECKED FOR POWER AT BREAKER JUNCTION BOX, NO POWER 0 VOLTS AT PIN 1 ON C1617E. VISUAL INSPECTION FOUND EYELET CAME APART FROM CIRCUIT SDC02 PER SERVICE MANAGER C.M INSTALLED LOCALLY ACQUIRED EYELET CRIMPED AND RE INSTALLED EYELET, VEHICLE STARTS PROPERLY AT THIS TIME.

Is that the connection I posted the picture of?

 

[joeman304]

I'm not 100% sure but it probably is. I haven't picked the truck back up yet since they still have to diagnose the issue with the Ford Pass app not connecting

 

[Nora]

Add mine to the list. 6700kms drove it for about 2 hours, 3 hours later, went to lock it for the night, no power, nothing. Next morning boosted it, drove it for 1.5 hours, came home, turned off the key, tried to restart, nothing again.
Turned off the Ford Pass App. Boosted it again, drove 20 minutes to the Ford dealer. Same thing. No power. Now she sits at the dealership waiting for Ford engineering. I will update once I get an answer!

 

[Nora]

Add mine to the list. 6700kms drove it for about 2 hours, 3 hours later, went to lock it for the night, no power, nothing. Next morning boosted it, drove it for 1.5 hours, came home, turned off the key, tried to restart, nothing again.
Turned off the Ford Pass App. Boosted it again, drove 20 minutes to the Ford dealer. Same thing. No power. Now she sits at the dealership waiting for Ford engineering. I will update once I get an answer!
[/QUOT

******UPDATE******
I will skip most of the minor details. joeman304 had the answer. It was the eyelet on the battery cable. It took 2 separate dealership service departments and engineering 10 days to figure it out, even though I mentioned it. Got the bandaid fix for now. New wiring harness on order.

 

[PaulCarver]

Does anyone know what the wire size is? I plan to buy a compression lug and fix it myself.

 

[MakinDoForNow]

Does anyone know what the wire size is? I plan to buy a compression lug and fix it myself.

There is at least one other thread covering the wire size and proper "lug" to use. Since this is part of a harness and it is not known if any other of the "lugs" have defects and it's under warranty why not let Ford fix it and keep u-dun-it issues out of the picture. If concerned about the 36 month warranty just purchase the extended or trade truck before month 36????

 

[Johnkn]

There is at least one other thread covering the wire size and proper "lug" to use. Since this is part of a harness and it is not known if any other of the "lugs" have defects and it's under warranty why not let Ford fix it and keep u-dun-it issues out of the picture. If concerned about the 36 month warranty just purchase the extended or trade truck before month 36????

The 8 year / 100,000 mile "Hybrid Unique" warranty applies


.

 

[MakinDoForNow]

The 8 year / 100,000 mile "Hybrid Unique" warranty applies


.

I assumed that the 12v harness was not part of the unique hybrid drive train with the longer warranty.

 

[Gullzway]

I assumed that the 12v harness was not part of the unique hybrid drive train with the longer warranty.

Not sure on that either, as this harness is the path that the Hybrid Battery charges the 12v Battery, I think.

 

[Johnkn]

Not sure on that either, as this harness is the path that the Hybrid Battery charges the 12v Battery, I think.

The 8 year / 100,000 mile warranty is for "Hybrid unique components if equipped"

Is that exact harness on a 2.0 Maverick or is it unique to the Hybrid?


.

 

[MakinDoForNow]

Not sure on that either, as this harness is the path that the Hybrid Battery charges the 12v Battery, I think.

I have a cheap digital voltage monitor in my dash power point and the voltages displayed closely follow that of a 12v deep cycle battery. Usually high of 14.7 or rarely 14.8 this is determined by the soc of the battery as the battery crosses 80-85% the voltage will gradually be reduced to reduce the rate of charge to prevent heat buildup and the possibility of over charging which is kiss of death. Anyway it appears that the portion of The 12v that the dash PowerPoint is on is part of the charging circuit and then one could expect that the entire 12v is on it. Presumably the voltage of the battery is taken at the battery which would require a signal wire to the dc/dc converter to set the desired voltage. I believe the voltage reading of the battery is the reason that the manual requires that no negative connections be attached to the negative battery post as they could possibility interfere with determining the doc of 12v battery. I certainly do not know how it actually works. This harness I believe would have to be used to charge the battery and is large enough to power everything.

 

[Darnon]

The 8 year / 100,000 mile "Hybrid Unique" warranty applies

Not for wiring harnesses. I've even read people report they were unable to get warranty coverage on their HV wiring.

Depending on your vehicle, electrical drivetrain system components covered by this warranty may include, and are not limited to: high-voltage battery, high-voltage battery connector, battery energy control module (BECM), on-board charger, inverter system controller (ISC), DC/DC converter, hybrid continuously variable transmission or electric driveline motor and transmission range sensor.

"Hybrid unique components" doesn't literally mean all components that aren't shared with the ICE-only version. Other notable exclusions are the high voltage A/C compressor.

BaseCare or higher Ford ESP ("extended warranty") does cover wiring harnesses, though.

 

[uga]

Who cares, Ford needs to issue a service advisory, TSB, or recall and fix/replace the harness! Sounds like this is going to fail on all Hybrid Mavericks unless its redesigned.

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