Sorry for the long delay, but I was able to get my FFE over to the Ford dealer on 3/22/22 and they installed the new (used) SOBDM that I purchased from the junkyard in Wyoming. Great News, it worked!!!
My FFE is now running great.
Just to review, on 10/19/21 my car stopped receiving a charge via the charging cable (still charged by regen braking). I took it to the Ford dealer, they said it needed a "new charging system." They quoted me about $4,500 for the repair, most of which was parts. I told them I didn't think the car (with 65K miles) was worth that much, so I brought the car back home (with about 20 miles remaining). I purchased a Forscan reader, plugged it up and got the following codes:
SOBDM DTC U3000:04-AB===
Code: U3000 - Control Module
Additional Fault Symptom:
- System Internal Failures
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC
Module: Secondary OBD Control Module A
Freeze Frame :
-REAL_TIME: 264771509 s - Global real time
-TOTAL_DIST: 110053.0 km - Total Distance
-MAIN_BCCM_VOLT: 12.00 V - Main ECU voltage supply
-EXTERIOR_TEMP: 20 °C - Outside temperature
-SOBDM_BECM_PSR: PSR On - SOBDM to BECM Wakeup Status
-PCM_SOBDM_PSR: PSR On - PCM to SOBDM Wakeup Status
-PWR_MODE_QF: Power Mode Undefined - Power Mode Quality Factor
-PWR_MODE_KEY: Key Out - Power Mode Key State
-INT_FAULT_CODE: 32 - Internal Fault Code
I went back to the dealer to ask more details. They said I needed a new charging cable harness. I asked about the SOBDM, they still said it was the harness, but that the part was no longer available and they could no longer repair it. I asked if they could repair it if I found the part myself. They said yes.
So I set about trying to find a charging harness. I called dealers in areas of the country where the FEE was primarily sold, with no success. No one sold a wiring harness alone, and none were listed as available on Ford's official parts website. I began wondering if I could rebuild it myself. Before attempting to do that, I ran diagnostic codes again with Forscan, but I noticed that there was absolutely NO mention of a wiring harness. I cleared the log, reset the DTC codes, and reset the modules. When I ran the scan again, all I was getting was a U3000:04 code, showing a problem with the SOBDM. I went back to the Ford dealer and they service rep again told me I needed a new "charger." I asked him for the part number. He said "the whole thing." I asked to speak to the specific mechanic (who received special training on the FFE). When they brought the mechanic up, he told me it was the SOBDM that was the bad part (not the "whole charging system," or the "charging harness" as the service rep was saying). Again, I clarified that they could install a used part if I found one. They said they would. I came back home and started searching, eventually finding a junk yard in Wyoming with 8 junked FFEs. I requested an SOBDM, sending them a image to make sure they were getting the right part (since they are also unfamiliar with EVs).
In the end, I paid $395 for the used SOBDM, including shipping, then $507 to have Ford install it, for a total of $902. Needless to say, I was thrilled to get it fixed for MUCH LESS than the original $4,500 that I was quoted.
I will try to upload invoices below