Refurbished Upper HV Battery, HELP with Start-up After Install

[slhutzley]

https://ibb.co/k2M37Qd
https://ibb.co/Ht5QMkB
https://ibb.co/KFPsjgv
https://ibb.co/3kMPkqy
https://ibb.co/w6kwvSL

[Anti_Climax]

TCM:
U0426:00-08 "invalid data received from vehicle immobilizer control module"
P1A0A:01-48 "Immediate shut down signal A: General electrical failure"
P0560:16-08 "System voltage: circuit voltage below threshold"
P060A:02-48 "Internal Control Module monitoring processor performance: general signal failure"
P060A:04-48 "Internal Control Module monitoring processor performance: system internal failure"
P1A0A:29-48 "Immediate shutdown signal A: Signal invalid"
PCM:
P0560:16-18 "system voltage low"
U0111:00-08 "Lost communication with battery energy control module A"
P061B:00-08 "Internal Control Module Torque Calculation performance"
P0AA0:01-8F "Hybrid/EV battery positive contractor circuit"
P1A13:00-08 - not listed

If that's just a subset of the errors, I'm going to go out on a limb and guess your canbus is shorted somewhere.

Can you list all the modules that are throwing codes?

Edit: the good news is that those don't appear to be broken pins, they are simply not populated. I can't be sure of the orientation (top, bottom, mirrored) but at least one matches up with those being unused and there's no indication they were there before.

[slhutzley]

These all have at least one code:
BECM
TCM
PCM
APIM
GFM
SASM
ABS
RCM
BDYCM
IPMB
FCIM
DDM
HVAC
RFA
ACM
IPC
GPSM

The following have no codes: OCS, DCDC, PAM, PSCM, GWM, PDM, SOBDM, ACCM

The links in the post above have pictures that show all of the codes. I didn't see a way to export them from Forscan.

[Anti_Climax]

So this is the CANBus layout (only slightly different for newer ones with DC charging). There are 4 busses exposed to the outside: EV HS-CAN, HS-CAN, MS-CAN and I-CAN. I believe there is another inside the battery itself. All the arrows that don't have a little resistor icon are unterminated connections to modules and the diagnostic socket. That gateway module passes traffic between busses and then each bus terminates at some other module. The BCM (same as BdyCM) also acts as a gateway to bridge traffic across busses.

If there is a short on one of those busses, you may see faults from modules that connect to it or no messages from them at all. You might also get codes from other modules if they are not getting data they expect, so you can see faults from modules on other busses as well.

EV HS-CAN Errors: BECM, PCM, GFM, ABS, TCM
No Errors: SOBDM, ACCM, DCDC, GWM

HS-CAN Errors: BCM, SASM, RCM
No Errors: OCS, PSCM, PAM, GWM

MS-CAN Errors: BCM, IPMB, RFA, IPC, DDM, HVAC, GPSM, APIM
No Errors: PDM, GWM

I-CAN Errors: IPC, FCIM, ACM, APIM
No Errors: GWM
Missing: TCU

Unfortunately, the selection of faults doesn't seem to narrow anything down. You might consider clearing all the faults and doing individual module diagnostics. Track down the service manual that has been linked in other threads and look up the codes. Strike out any module fault codes that don't clearly indicate a problem in the module itself like "low input voltage". Hopefully that narrows things down further.

[skyguy_6153]

For the BECM DTC "U3000:46" that you're getting in one of your pics, have you already did a self test on the BECM yet with Forscan after rebuilding the battery pack? If not, clear the current DTCs, and then run the self test on the BECM. (see second pic for more info from FFE workshop manual)

[slhutzley]

For the BECM DTC "U3000:46" that you're getting in one of your pics, have you already did a self test on the BECM yet with Forscan after rebuilding the battery pack? If not, clear the current DTCs, and then run the self test on the BECM. (see second pic for more info from FFE workshop manual)

No I have not. I only did the removal and reinstalling of the pack. I shipped the battery to EnerZ in California to rebuild the pack and remove the coolant paths. I was told it should be plug and play from there.

[Anti_Climax]

A lot of codes will persist even if they get addressed, so you should clear them all and rescan any time you're checking. Just make sure to note down what's there first, in case something is intermittent and doesn't readily re-trigger.

[slhutzley]

For the U3000:46 Code, the Action is:
"CLEAR all BECM Diagnostic Trouble Codes (DTCs). REPEAT the BECM self-test. If DTC U3000:46 returns, INSTALL a new upper and lower high voltage battery."

I am going to do the BECM self-test tonight. I am reading this correctly, that if the code persists after the self-test the upper battery is still bad and needs to be replaced?

[Anti_Climax]

Keep in mind that the troubleshooting they have there is specifically for Ford service techs. They don't crack open batteries to repair so if it's something internal, their only "fix" is replacing it.

If it persists your options are replacement or deeper analysis that Ford won't help with.

[slhutzley]

Update: Yesterday I cleared the DTC, ran the BECM self test, and ran the BECM check voltage tests.

All of the cell voltages came back in the normal range, and a lot of the codes went away. In fact, after running the test, instead of getting the generic "Stop Safely Now" message, I now am getting "Battery Depleted. Stop Safely Now."

So I plugged in my level 2 charger to see if it would take a charge. According the charger, it was charging at normal rate. However, according to the car, it sensed that it was plugged in (yellow charge light on the dash), but when the charger was plugged in, the blue rings circled twice, then when dark (no pulsing to indicate charging). I decided to leave it overnight to see what happened - maybe it was too depleted to show the first charge ring. But this morning, still no charge ring. I had to go to work, so no further testing.

Here are the codes it read last night:
PCM U0111:00
PCM P0AA0:01
GFM U0111:00
TCU U3003:16
IPC U0412:82

I plan on researching these in the service manual at work today to see if any more clues can be found. Any help is appreciated.