mattbrown
Posts: 11
Joined: Thu Jul 10, 2014 11:02 am
Location: London, Ontario, Canada

HV Battery Issues - Out of Warranty

Thu Nov 19, 2020 12:15 pm

An EV nightmare coming true

Three weeks ago while my wife was driving our 2012 FFE, the Yellow Wrench symbol appeared. The car drove home fine and she parked it for the evening. In the morning I drove my car to work (30 kms) without warnings, plugged into the Level 2 charger at work and went about my day. After work I unplugged the charger and went to starting the car as normal. I had no power on the dash and flashing/flicker dimly LED running lights. I placed the car back on the level 2 charger and now could start the car to accessory mode, but the running lights would quickly begin flashing and flickering again. The Yellow Wrench warning was back and I also noticed the car hadn't charge after being plugged in for 8 hours on "charge now".

I have read forum posts about 12v battery issues and since my FFE still had the original 12v battery, I assumed this was a 12v issue. I took a work truck home and returned the next day with a multimeter. After reading 10.2 v over the battery terminals, I went to the local ford dealer, bought a 12v battery and replaced the 12v battery. With the car of the charger, I started the care and immediately got the SSN and Yellow Wrench warnings. Cycle the car on and off a few times with no difference. This is when I realized how bad things were and I had CAA tow my car to my local Ford dealer.

So far the tech has done or confirmed the following:
- The original 12v battery was bad (tested 62 CCA, spec is 390 CCA)
- Over 50 error codes were found on a Memory Test of all modules
- Vehicle would drive in shop after codes cleared, but SSN message came on for the tech
- Completed on demand tests on: PCM, TCM and BECM all pass with memory codes (PCM - P0AA0, BECM - P0AA6, TCM - P1A0A)
- Tech cleared module memory codes and road tested, Yellow Wrench came back on, checked modules and codes are back (PCM - P0AA0, BECM - P0AA6, TCM - P1A0A).
- Upper High Voltage battery has failed coolant leak inspection

That is the current status of my FFE. The dealership is waiting to hear back from Ford service engineering before providing a repair estimate. I am guessing this will be a HV battery replacement. My car was a Ford press vehicle and it's warranty started May 2012, it has 111000 kms (69,000 is miles) and is out of of warranty by 4 months :cry: My FFE already had all recall orders completed, including the bulletin for the lower HV connection. My car had corrosion on this connection and the battery was shipped to MI for repairs.

I will post the repair estimate when I get it, but I highly doubt it will be economical to repair this car. I hope for others this doesn't become a reoccurring issue out of warranty
2012 FFE - Platinum White AKA "Vanna White"
2008 Saab 9-3 wagon - Charcoal Grey

skyguy_6153
Posts: 18
Joined: Sat Jun 20, 2015 4:55 am

Re: HV Battery Issues - Out of Warranty

Thu Nov 19, 2020 7:28 pm

I had the exact same problem, and I did a write up on fixing mines recently. The leak causes an isolation fault rendering the pack useless until you go in remove the modules, clean all the leaked coolant out, remove heat exchangers (cooling plates) between each cell in each module, dry off the bus bars, wires, and components that got wet, and reassemble. When you reassemble, leave the heat exchangers, cooling lines, and cooling assembly out of the upper pack, and make a bypass loop so the coolant flow can continue to the rest of the car. Ford wanted $14,000 to replace my pack (I was also out of warranty), luckily Im doing an EV conversion and learned how to take apart a high voltage battery pack from a Nissan Leaf, so the FFE was fairly simple to do.
2012 Focus Electric with DIY P0A0A fix "coolant leak inside battery" (removed coolant hoses, heat exchangers, and cooling assembly from upper battery pack) over 1000+ miles and no problems yet :D

scottt
Site Moderator
Posts: 347
Joined: Mon Apr 06, 2015 6:00 am

Re: HV Battery Issues - Out of Warranty

Fri Nov 20, 2020 5:04 am

If you're out of warranty by only 4 months, call Ford yourself. I had a PT Cruiser that was just out of warranty. Power steering pump started leaking. Was going to be $1500 to repair. Called Chrysler, they said you pay $150, we'll pay the rest, and they did.

Can't hurt.
2015 Magnetic FFE (aka Magneto) - Retired
2017 Kona Blue FFE (aka King Kona) - Current

mattbrown
Posts: 11
Joined: Thu Jul 10, 2014 11:02 am
Location: London, Ontario, Canada

Re: HV Battery Issues - Out of Warranty

Fri Nov 20, 2020 6:05 pm

scottt wrote:
Fri Nov 20, 2020 5:04 am
If you're out of warranty by only 4 months, call Ford yourself. I had a PT Cruiser that was just out of warranty. Power steering pump started leaking. Was going to be $1500 to repair. Called Chrysler, they said you pay $150, we'll pay the rest, and they did.

Can't hurt.
I have already contacted Ford directly and I am moving my way up through Ford customer service ladder hopefully it will bear fruit. It definitely doesn't hurt to try at this point.

Thanks for responding.
2012 FFE - Platinum White AKA "Vanna White"
2008 Saab 9-3 wagon - Charcoal Grey

mattbrown
Posts: 11
Joined: Thu Jul 10, 2014 11:02 am
Location: London, Ontario, Canada

Re: HV Battery Issues - Out of Warranty

Fri Nov 20, 2020 6:27 pm

skyguy_6153 wrote:
Thu Nov 19, 2020 7:28 pm
I had the exact same problem, and I did a write up on fixing mines recently. The leak causes an isolation fault rendering the pack useless until you go in remove the modules, clean all the leaked coolant out, remove heat exchangers (cooling plates) between each cell in each module, dry off the bus bars, wires, and components that got wet, and reassemble. When you reassemble, leave the heat exchangers, cooling lines, and cooling assembly out of the upper pack, and make a bypass loop so the coolant flow can continue to the rest of the car. Ford wanted $14,000 to replace my pack (I was also out of warranty), luckily Im doing an EV conversion and learned how to take apart a high voltage battery pack from a Nissan Leaf, so the FFE was fairly simple to do.
SkyGuy,

That is some impressive next level DIY work. I am not an electrical genius, but I know my way around basic wiring and electrical safety. I regularly work inside live 600V panels at work to diagnose controls issues on refrigeration equipment. I am going to pursue getting an exemption on my warranty first, but if that fails I will be considering your DIY fix. I read through your upper pack removal write up, did you do any sort of write up on reconditioning the upper pack? The basic concept sounds similar to repairing a water damaged phone, remove the moisture, clean anything that could be causing a short and reassemble.

Thanks for replying, and I may be in touch if I strike out with Ford corporate
2012 FFE - Platinum White AKA "Vanna White"
2008 Saab 9-3 wagon - Charcoal Grey

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