Well, Triangles, you were right. Over the past month, I've gotten increasingly frequent SSN notifications. It has been "stalling" at least once a day, thankfully in stop-and-go traffic where it annoyed other drivers who had to go around me, but didn't present an immediate threat to anyone. The problem is, I don't trust the car now. I can't find any pattern, either. It stalls when fully charged, and it stalls when 30% discharged. It stalls in the rain, it stalls when it's dry. Warm, cold, doesn't matter. Every time I come to a stop I wonder if the car is going to move again.triangles wrote: ↑Wed Dec 05, 2018 10:25 amHate the be the bearer of bad news but it will happen again and the problem will only get worse until you cannot drive it at all. Usually this is related to corrosion with one of the high voltage plugs or damage to a safety wire that goes along side the HV wires to detect if a HV wire has been cut. What happened is the car detected a fault with the HV system so it disengaged the battery contactors to prevent any HV from leaving the HV battery. That is why you couldn't go anywhere but the car still appeared to be on. It is also possible that your problem is with the battery or Traction Control Module (TCM). The TCM is the assembly that contains the motor, inverter, HV junction box, and gearbox. Unfortunately the FFE's error logging and self diagnostics leave a lot to be desired, so I wouldn't be surprised if the dealer can find nothing wrong. It's like the thought of having to chase down intermittent faults never crossed Ford's minds when they designed the FFE. It may be counter intuitive but hopefully your FFEs fault goes from intermittent to consistent so they can actually figure out what is wrong. Keep us updated as to what they find.
I finally got it to the dealership. They've had it for over a week now. The service adviser called the other day and said they couldn't replicate the problem, and that I should pick up the car and return it to them if the SSN failure happened again. I told him that was unacceptable, that it was failing daily for me and thus unsafe to drive. It's absolutely frustrating that it has been stalling for me every day, sometimes multiple times each day, but it's apparently working fine for the dealership tech. I believe him, too, because I get the "EV has a warning light" push notification on my phone whenever the SSN failure occurs. They've driven it about 76 miles in that time, with a couple of 30-40 mile trips and a few short jaunts. What could they possibly be doing differently from what I do every day?
To be fair, the dealership has been supportive. I'm certain they believe me about the failures (I've sent images and screenshots). They're providing a loaner. When I pushed back about driving the car until it failed again they accepted it without argument. We'll see how it goes from here. Hopefully they can induce a failure and diagnose the problem. I'm more concerned about the dealership *not* being able to diagnose and repair the problem. What happens then?