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 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