Taliesin77
Posts: 4
Joined: Wed Dec 05, 2018 8:39 am

Re: "Stop Safely Now" -- my 2016 FFE stalled twice

Mon Jun 10, 2019 11:20 am

triangles wrote:
Wed Dec 05, 2018 10:25 am
Hate 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.
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.

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?

shniestEV
Posts: 71
Joined: Tue Nov 24, 2015 2:14 pm
Location: Vancouver

Re: "Stop Safely Now" -- my 2016 FFE stalled twice

Mon Jun 10, 2019 12:37 pm

In a similar situation

viewtopic.php?f=15&t=900&start=670#p31931

PM me for more info.
2016 Magnetic FFE - Canada

Taliesin77
Posts: 4
Joined: Wed Dec 05, 2018 8:39 am

Re: "Stop Safely Now" -- my 2016 FFE stalled twice

Wed Jun 19, 2019 7:15 am

The dealership had my FFE for about 2 weeks. In that time they drove the car just over 200 miles. They were unable to replicate the failure. They also ran diagnostics and were unable to find any issues. I can't fault them for that -- they really did try to find the problem. Incredibly frustrating, though, that it would happen for me *every day* and wouldn't happen for them *once* in 2 weeks and 200 miles! How is that even possible?

Wracking my brain, trying to figure out what's different between the two situations, and I can't identify anything. My first thought was maybe driving on the Turnpike (high speed) for any significant time/distance causes problems. Most of the failures occur at the end of my trip, either near home or near work. However, some failures happen within the first few minutes of driving or when I'm driving around town, so I can rule out the "highway speeds" possibility. What else could there be? It seems completely random.

Anyhow, the dealership had exhausted their efforts, so I picked the car up this morning and drove to work. About 1/4 mile from work, on the Turnpike exit ramp, I got the SSN failure again!!! As usual, the car recovered in a few minutes and I was able to complete the trip to work.

So now what? With the dealership unable to find the problem or replicate the failure, what do I do? I can't keep driving the car in this condition.

scottt
Site Moderator
Posts: 312
Joined: Mon Apr 06, 2015 6:00 am

Re: "Stop Safely Now" -- my 2016 FFE stalled twice

Thu Jun 20, 2019 3:42 am

I know this sounds a bit weird.....

How about setting up a dash cam to capture your drive and hopefully the dashboard. Not sure if that would help the dealer or not to watch your video.
2015 Magnetic FFE (aka Magneto) - Retired
2017 Kona Blue FFE (aka King Kona) - Current

Taliesin77
Posts: 4
Joined: Wed Dec 05, 2018 8:39 am

Re: "Stop Safely Now" -- my 2016 FFE stalled twice

Thu Jun 20, 2019 7:55 am

scottt wrote:
Thu Jun 20, 2019 3:42 am
I know this sounds a bit weird..... How about setting up a dash cam to capture your drive and hopefully the dashboard. Not sure if that would help the dealer or not to watch your video.
Not weird at all. I've considered doing it, although I don't think it wouldn't help them at all. I don't think they doubt me, so I don't feel the need (at this point) to prove anything beyond what I have already done. The dealership I purchased the car from (and who attempted the diagnosis) has taken the car back to do more testing, so hopefully they'll uncover something.

The car did give them a failure code: PA0A0A (or something like that). From what I can tell, it's somewhat of a generic code that sets off the SSN warning. It only tells them that there was a trouble code related to the high voltage system, but it doesn't specify the actual problem.

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