Did I Just Blow My 3rd (and updated part) HVBJB???

[Hammered]

It is my perception that the HVBJB is within the sealed battery case, and therefore not accessible for external cooling. Can someone confirm or deny my perception?

EV batteries (sans the air battery) are sealed and contain a gortex patch to allow moisture to escape and the battery to 'breathe' -- While gortex allows water vapor through, water itself cannot enter it. So it's sealed to everything except gases essentially.

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[cvk71]

Newberg Ford finished the car yesterday and I picked it up last night. The repair took 9 days, but some of those days were due to the field engineer coming out to look at the car and another big project their EV tech was involved with on a transit van they had in the shop at the same time.

This was my first time at Newberg Ford, but it will now be the dealer I go to for any future service/repairs.. Their EV tech‘s attention to detail is very impressive and after talking to him a little bit I feel very comfortable having him work on the car. The staff was also awesome. The service manager was there at pick up and asked about how I learned so much about the car. When I showed them the forum I could tell they were pretty impressed on how much info we have here and I wouldn’t be surprised if it becomes another reference for them in the future when it comes the the MME.

The dealer I have mine at tried to do the "we just have to reset it" and I told him what happened on the forum when they tried that and he changed his tune. Called me yesterday and said I am patient zero on this failing again. I just let it go because there was no point in telling him that I am not the first.

 

[cvk71]

Tesla had problems with melted contactors in the P85 Model S back around 2015. They upgraded the contactors to Inconel contacts which solved the problem and added ludicrous mode. Very similar to how Ford upgraded the contactors in the new part.

Here is a Model Y contactor assembly (similar to our HVBJB): https://www.ebay.com/itm/165575147430
And these are the contactors they use: https://www.sensata.com/sites/defau...ac-gv35-sereies-800v-contactors-datasheet.pdf

They can handle 1000 amps (max output for a GTPE) for 90 seconds. Ours are rated for 60 seconds.

The Tesla assembly uses much thicker bus bars than our HVBJB so it probably has better heat dissipation and greater thermal capacity. Ford could do the same with our HVBJB, I think some thicker bus bars would do the trick (I suggest going from 3mm to 5mm thick busbar).

Is this somehow related to the 5 second limit or at least contributing to it somehow?

 

[dtbaker61]

The dealer I have mine at tried to do the "we just have to reset it" and I told him what happened on the forum when they tried that and he changed his tune. Called me yesterday and said I am patient zero on this failing again. I just let it go because there was no point in telling him that I am not the first.

reset is not a fix
Have them look up TSB-22-2178

 

[Mach-Lee]

Is this somehow related to the 5 second limit or at least contributing to it somehow?

Not really, the 5 second limit is due to limitations in the entire pack, not just the HVBJB. It is a "next weakest link" situation, just replacing one component will cause another to be the next weakest link until the pack is completely redesigned for a larger sustained current capacity.

 

[heisnuts]

The dealer I have mine at tried to do the "we just have to reset it" and I told him what happened on the forum when they tried that and he changed his tune. Called me yesterday and said I am patient zero on this failing again. I just let it go because there was no point in telling him that I am not the first.

I think the hardest part is finding a good dealer. Now that I have that, I feel a lot better about it.

This morning's trip to work was awesome. The MME automatically pre-conditioned like it is set to do, I got into a warm car, and I had that instant acceleration and regen braking that I was sorely missing over the last 9 days as I was "forced" back to using our ICE vehicle at the house. Like I have said before, I don't think I could ever go back to gas for a daily driver.

 

[Scooby24]

Newberg Ford finished the car yesterday and I picked it up last night. The repair took 9 days, but some of those days were due to the field engineer coming out to look at the car and another big project their EV tech was involved with on a transit van they had in the shop at the same time.

This was my first time at Newberg Ford, but it will now be the dealer I go to for any future service/repairs.. Their EV tech‘s attention to detail is very impressive and after talking to him a little bit I feel very comfortable having him work on the car. The staff was also awesome. The service manager was there at pick up and asked about how I learned so much about the car. When I showed them the forum I could tell they were pretty impressed on how much info we have here and I wouldn’t be surprised if it becomes another reference for them in the future when it comes the the MME.

Did they give any indication as to why the new part might have failed?

 

[heisnuts]

Did they give any indication as to why the new part might have failed?

They did not. I don't think there is really anyway for them to tell at the dealership level. I am sure Ford will want the old part sent back to them for teardown, which hopefully will give them more answers. Hopefully this early case (along with the data the field engineer pulled from the car during the repair) will provide valuable data for future redesigns... At least that is my hope.

 

[cvk71]

reset is not a fix
Have them look up TSB-22-2178

They are fixing it properly now, parts are on order. I will still pass that on to them though, thanks.

 

[cvk71]

Not really, the 5 second limit is due to limitations in the entire pack, not just the HVBJB. It is a "next weakest link" situation, just replacing one component will cause another to be the next weakest link until the pack is completely redesigned for a larger sustained current capacity.

That's unfortunate but not a deal breaker. The real problem is I have to give the dealer a list of things not working every time I take it in and it's not a short list.

 

[mkhuffman]

They are fixing it properly now, parts are on order. I will still pass that on to them though, thanks.

Is your failed HVBJB the new robust part, or the old one?

 

[cvk71]

Is your failed HVBJB the new robust part, or the old one?

I'm not 100% sure. My first one happened on 4/26/22 so I think it's the old one.

 

[Chris-MMEX_GT500]

Mine goes in next Tuesday to begin the HVBJB replacement, so far the BEV rep was very professional and helpful. Hope the OP's issues are a thing of the past.

 

[Hammered]

I think the hardest part is finding a good dealer. Now that I have that, I feel a lot better about it.

This morning's trip to work was awesome. The MME automatically pre-conditioned like it is set to do, I got into a warm car, and I had that instant acceleration and regen braking that I was sorely missing over the last 9 days as I was "forced" back to using our ICE vehicle at the house. Like I have said before, I don't think I could ever go back to gas for a daily driver.

Finding a good dealer is like finding a unicorn eating from the pot of gold at the end of the rainbow.

 

[mkhuffman]

Finding a good dealer is like finding a unicorn eating from the pot of gold at the end of the rainbow.

That's funny but my local dealer is one of the good ones. Their service has been excellent every time I have been there, and the sales experience was smooth and easy. When I got my GT from another dealer out of state, they refunded my nonrefundable deposit no questions asked.

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