Cold Weather Is Killing the Old HVBJBs

[Mach-Lee]

Just a heads up, I’ve confirmed quite a few cases of original HVBJBs failing in the past week. The cold weather tends to make the contactors stick more. If you own a 2021 or 2022 vehicle with the original HVBJB and haven’t taken it in for the 23S56 HVBJB replacement recall, you should do so immediately. Apparently, there are still many of these original HVBJBs out there that haven’t been replaced for various reasons. According to NHTSA documents, about 26.6% or one-quarter of recalled vehicles still have not gotten the HVBJB replaced yet.

Many owners mistakenly believed that their issue was with the 12V battery. However, I want to remind everyone that when the HVBJB fails and the contactors stick, the 12V battery can no longer be charged and will either drain or go dead. It may appear as though the 12V battery is faulty, but it’s because it can't be recharged from the high voltage battery the fault occurs. The root cause of the problem is the HVBJB. In some cases, the contactor can stick intermittently and won’t always display warning codes.

If your car with an active 23S56 recall won’t start, charge, or has a “Stop safely now” error, there’s a good chance that the HVBJB is the problem, not the 12V battery. Unplug it and walk away for 10 minutes, then try to start it again. If it still won't start, you’ll need to have your car towed to a dealer. Despite some dealers’ claims, HVBJB parts for all affected vehicles have been readily available and in stock at the part warehouses for quite some time now. Don’t let this situation leave you stranded in a parking lot. Call your dealer and get the replacement done as soon as possible if you haven't yet. If your dealer is being unreasonable, consider taking your car to another dealer.

Check your VIN here: https://www.ford.com/support/recalls/

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[pr0t0c0l_dr01d]

This sounds like exactly what happened to mine. I’m not surprised to see this post - I’ve seen a couple of other posts about failed modules and I suspected the extreme cold had something to do with this.

 

[macchiaz-o]

Apparently, there are still many of these original HVBJBs out there that haven’t been replaced for various reasons.

RWD SR isn't included in the recall, yet. Hopefully you're not seeing a significant increase from that trim level?

 

[Mach-Lee]

RWD SR isn't included in the recall, yet. Hopefully you're not seeing a significant increase from that trim level?

They've all been extended packs this week, most under recall still.

 

[likescookies]

They've all been extended packs this week, most under recall still.

Alas, I'm in Minneapolis with a standard range RWD 2021 (thus not subject to the recall) and our HVBJB failed on Tuesday during the bitter cold. Dealer is replacing it now.

 

[Js1tr3]

Looks like I'll be in the same boat, 2021 AWD standard range, had to be towed to the dealer. charged the battery to pull codes, but couldn't drive to get it to the garage. been two days but they haven't even looked at it yet.

 

[Js1tr3]

Here are the Codes I pulled before the Tow.

Any Advice? are these consistent with the HVBJB failure

===SOBDMB DTC P0DA8:00-AF===
Code: P0DA8 - Hybrid/EV Battery Voltage/Drive Motor 'A' Inverter Voltage Correlation

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Secondary OBD Control Module B

Freeze Frame #1:
-EVENT_TIME: 126765885 s (Wed Jan 22 14:38:36 2025) - Event time
-OUTDOOR_TEMPERATURE: -12 °C - Outside temperature

===END SOBDMB===

===SOBDMC DTC P0D2D:00-AF===
Code: P0D2D - Drive Motor 'A' Inverter Voltage Sensor 'A' Circuit

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Secondary OBD Control Module C

Freeze Frame #1:
-EVENT_TIME: 126765885 s (Wed Jan 22 14:38:36 2025) - Event time
-TOTAL_DISTANCE: 42383 km - Total Distance
-MODULE_VOLTAGE: 14.0 V - Control Module Voltage
-OUTDOOR_TEMPERATURE: -12 °C - Outside temperature

===END SOBDMC===

===SOBDMC DTC P1A10:00-AF===
Code: P1A10 - Hybrid Powertrain Control Module - Battery Disabled

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Secondary OBD Control Module C

Freeze Frame #1:
-EVENT_TIME: 126765884 s (Wed Jan 22 14:38:35 2025) - Event time
-TOTAL_DISTANCE: 42383 km - Total Distance
-MODULE_VOLTAGE: 14.0 V - Control Module Voltage
-OUTDOOR_TEMPERATURE: -12 °C - Outside temperature

===END SOBDMC===

===SOBDMC DTC U351F:00-2F===
Code: U351F - High Voltage System Interlock Circuit 'E' Low

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Secondary OBD Control Module C

Freeze Frame #1:
-EVENT_TIME: 126765890 s (Wed Jan 22 14:38:41 2025) - Event time
-TOTAL_DISTANCE: 42383 km - Total Distance
-MODULE_VOLTAGE: 14.0 V - Control Module Voltage
-OUTDOOR_TEMPERATURE: -12 °C - Outside temperature

===END SOBDMC===

===BECM DTC U0594:00-2F===
Code: U0594 - Invalid Data Received From Hybrid/EV Powertrain Control Module 'A'

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Battery Energy Control Module

Freeze Frame #1:
-EVENT_TIME: 126765890 s (Wed Jan 22 14:38:42 2025) - Event time
-TOTAL_DISTANCE: 42383 km - Total Distance
-MODULE_VOLTAGE: 14.2 V - Control Module Voltage
-VSS: 0.0 km/h - Vehicle Speed
-RPM: 0 1/min - Engine Revolutions Per Minute

===END BECM===

===SOBDM DTC ===
Successful DTC reading, no error codes found

Module: Secondary OBD Control Module A
===END SOBDM===

===PCM DTC ===
Successful DTC reading, no error codes found

Module: Powertrain Control Module
===END PCM===

===OBDII DTC ===
Successful DTC reading, no error codes found

Module: On Board Diagnostic II
===END OBDII===

===ACCM DTC ===
Successful DTC reading, no error codes found

Module: Air Conditioning Control Module
===END ACCM===

===SODR DTC ===
Successful DTC reading, no error codes found

Module: Side Obstacle Detection Control Module - Right
===END SODR===

===SODL DTC ===
Successful DTC reading, no error codes found

Module: Side Obstacle Detection Control Module - Left
===END SODL===

===CMR DTC B115E:97-8F===
Code: B115E - Camera Module

Additional Fault Symptom:
- Component Or System Operation Obstructed Or Blocked

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Camera Module Rear
===END CMR===

===CMR DTC B15E1:97-8F===
Code: B15E1 - Driver Side LED

Additional Fault Symptom:
- Component Or System Operation Obstructed Or Blocked

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Camera Module Rear
===END CMR===

===CMR DTC B15E2:97-8F===
Code: B15E2 - Passenger Side LED

Additional Fault Symptom:
- Component Or System Operation Obstructed Or Blocked

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Camera Module Rear
===END CMR===

===CCM DTC ===
Successful DTC reading, no error codes found

Module: Cruise Control
===END CCM===

===ABS DTC U023A:00-2E===
Code: U023A - Lost Communication With Image Processing Module 'A'

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Antilock braking system

Freeze Frame #1:
-TOTAL_DISTANCE: 42383 km - Total Distance
-OUTDOOR_TEMPERATURE: -11 °C - Outside temperature
-POWER_MODE: Undefined - Power Mode Status
-ABS: Inactive - ABS
-AYC: Inactive - AYC
-BTCS: Inactive - BTCS -201D
-HDC: Inactive - HDC
-RSC: Inactive - RSC
-BTC: Inactive - BTC

===END ABS===

===ABS DTC U0594:00-2F===
Code: U0594 - Invalid Data Received From Hybrid/EV Powertrain Control Module 'A'

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Antilock braking system

Freeze Frame #1:
-EVENT_TIME: 126765886 s (Wed Jan 22 14:38:38 2025) - Event time
-TOTAL_DISTANCE: 42383 km - Total Distance
-MODULE_VOLTAGE: 14.0 V - Control Module Voltage
-OUTDOOR_TEMPERATURE: -11 °C - Outside temperature
-POWER_MODE: Ignition on power mode - Power Mode Status
-ABS: Inactive - ABS
-AYC: Inactive - AYC
-BTCS: Inactive - BTCS -201D
-HDC: Inactive - HDC
-RSC: Inactive - RSC
-BTC: Inactive - BTC

===END ABS===

===ABS DTC U0140:00-2E===
Code: U0140 - Lost Communication With Body Control Module

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Antilock braking system

Freeze Frame #1:
-TOTAL_DISTANCE: 42383 km - Total Distance
-OUTDOOR_TEMPERATURE: -11 °C - Outside temperature
-POWER_MODE: Undefined - Power Mode Status
-ABS: Inactive - ABS
-AYC: Inactive - AYC
-BTCS: Inactive - BTCS -201D
-HDC: Inactive - HDC
-RSC: Inactive - RSC
-BTC: Inactive - BTC

 

[Acadiadad]

My 2021 Premium AWD standard range HVBJB and LVB failed and were replaced 2 weeks ago.

 

[drakeymcd]

What if I have a ‘22 (manufactured 01/22) that has no active recalls or previous work/history with the HVBJB? I purchased it with ~60K miles and no issues so far.

 

[HuntingPudel]

What if I have a ‘22 (manufactured 01/22) that has no active recalls or previous work/history with the HVBJB? I purchased it with ~60K miles and no issues so far.

That’s a weird one. It should be affected by the recall since the revision of the HVBJB didn’t happen until late May of 2022 and there is no history of the HVBJB having been serviced. Either that, or the HVBJB has been serviced and the record is somehow missing from the service history.

 

[Donna216]

2021 Standard Gt, here.
Sent mine in on January 20th. Didn't fail. It was scheduled months ago for that day. Part ordered on January 20th. Still waiting. Gratefully, my dealer has provided transportation for awhile.

 

[drakeymcd]

That’s a weird one. It should be affected by the recall since the revision of the HVBJB didn’t happen until late May of 2022 and there is no history of the HVBJB having been serviced. Either that, or the HVBJB has been serviced and the record is somehow missing from the service history.

interesting, it was a lemon/buyback but from what was checked for me in the service history, there was no mention of any recall or issues with HVBJB.

 

[GreaseMonkey]

Just a heads up, I’ve confirmed quite a few cases of original HVBJBs failing in the past week. The cold weather tends to make the contactors stick more. If you own a 2021 or 2022 vehicle with the original HVBJB and haven’t taken it in for the 23S56 HVBJB replacement recall, you should do so immediately. Apparently, there are still many of these original HVBJBs out there that haven’t been replaced for various reasons.

Many owners mistakenly believed that their issue was with the 12V battery. However, I want to remind everyone that when the HVBJB fails and the contactors stick, the 12V battery can no longer be charged and will either drain or go dead. It may appear as though the 12V battery is faulty, but it’s because it can't be recharged from the high voltage battery the fault occurs. The root cause of the problem is the HVBJB. In some cases, the contactor can stick intermittently and won’t always display warning codes.

If your car with an active 23S56 recall won’t start, charge, or has a “Stop safely now” error, there’s a good chance that the HVBJB is the problem, not the 12V battery. Unplug it and walk away for 10 minutes, then try to start it again. If it still won't start, you’ll need to have your car towed to a dealer. Despite some dealers’ claims, HVBJB parts for all affected vehicles have been readily available and in stock at the part warehouses for quite some time now. Don’t let this situation leave you stranded in a parking lot. Call your dealer and get the replacement done as soon as possible if you haven't yet. If your dealer is being unreasonable, consider taking your car to another dealer.

Check your VIN here: https://www.ford.com/support/recalls/

Lee, Ford should begin compensating you for your efforts. You’re saving their ass at this point.

 

[Jack Roberts]

Just a heads up, I’ve confirmed quite a few cases of original HVBJBs failing in the past week. The cold weather tends to make the contactors stick more. If you own a 2021 or 2022 vehicle with the original HVBJB and haven’t taken it in for the 23S56 HVBJB replacement recall, you should do so immediately. Apparently, there are still many of these original HVBJBs out there that haven’t been replaced for various reasons.

Many owners mistakenly believed that their issue was with the 12V battery. However, I want to remind everyone that when the HVBJB fails and the contactors stick, the 12V battery can no longer be charged and will either drain or go dead. It may appear as though the 12V battery is faulty, but it’s because it can't be recharged from the high voltage battery the fault occurs. The root cause of the problem is the HVBJB. In some cases, the contactor can stick intermittently and won’t always display warning codes.

If your car with an active 23S56 recall won’t start, charge, or has a “Stop safely now” error, there’s a good chance that the HVBJB is the problem, not the 12V battery. Unplug it and walk away for 10 minutes, then try to start it again. If it still won't start, you’ll need to have your car towed to a dealer. Despite some dealers’ claims, HVBJB parts for all affected vehicles have been readily available and in stock at the part warehouses for quite some time now. Don’t let this situation leave you stranded in a parking lot. Call your dealer and get the replacement done as soon as possible if you haven't yet. If your dealer is being unreasonable, consider taking your car to another dealer.

Check your VIN here: https://www.ford.com/support/recalls/

My HVBJV failure occurred right after the recall announcement. I don’t know if it was replaced with the new part or an original.

 

[mach-ebert]

Can confirm. Working with the BEV team to get my car to the dealer to have the recall performed. Here's to hoping THIS time they can actually complete the recall.

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