High voltage / Powertrain Malfunction (2024 premium)

[Mach-Lee]

It seems that due to failure frequency, it is undersized for load during normal operation. If the contactors are melting, it probably should have been a larger size. If we had engineered it, we probably would have chosen the 3000A Contactor. Although, our goal is bullet proof, not marginally acceptable.

Do you know how big a 3000A high voltage DC contactor is? I have to LOL at the 3000A idea, no way that's gonna fit (there are four of them BTW). Realistically you'd only go up a size to 750A but that will also cause packaging issues that could mean a complete battery pack redesign. 500A is adequate for the design with proper heat sinking and software that limits current duration. If anything, Ford should switch suppliers of 500A contactors.

So could it be an issue possibly with the high voltage wire connections not being crimped well enough causing excess heat due to resistance? I’ve dealt with this issue on high wattage inverters. Mainly on the battery side into the inverters.

No, all those connections are crimped and torqued by computer in automative assembly so it would be very difficult to have a loose connection. Different than electrical work that is done in the field by hand with no QC data from the tools. Contactors were all torqued exactly to spec on the HVBJB I dissembled. If there were loose connections, there would probably be melted cables in the battery compartment, and that hasn't been observed.

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[capsails]

The ones I looked up were 3”x4”x5”

 

[EnergyVampire]

Update: Finally got My car back. Hopefully that's the last time this happens.

 

[Mr_Mercedes]

Update: Finally got My car back. Hopefully that's the last time this happens.

Hope so. Still impatiently waiting for mine to be fixed. Waiting on the buyback paperwork.

 

[HughJazzol]

I just got this message after rolling backwards in neutral from my driveway. My driving mode got disengaged and grayed out , and the car rolled forward on its own when put on D. I restarted it, and I got my engage mode back with 1 pedal driving. An orange wrench remains on the display and the app warned me.
Is there a doubtful possibility that this will clear on its own being a fluke? Or do I need to schedule service immediately?

More importantly, can I drive it?

 

[cbcasas]

I just got this message after rolling backwards in neutral from my driveway. My driving mode got disengaged and grayed out , and the car rolled forward on its own when put on D. I restarted it, and I got my engage mode back with 1 pedal driving. An orange wrench remains on the display and the app warned me.
Is there a doubtful possibility that this will clear on its own being a fluke? Or do I need to schedule service immediately?

More importantly, can I drive it?

Sounds like a malfunction more than anything. Leave the car alone for 15 mins and it may clear. Otherwise pull the codes from the OBD and post them here

 

[HughJazzol]

Sounds like a malfunction more than anything. Leave the car alone for 15 mins and it may clear. Otherwise pull the codes from the OBD and post them here

I don't have the obd hardware and was just reading a guide for it and the list of mods that have been accomplished.

 

[EnergyVampire]

Update #2:
Well. A month or so later now and the replacement has failed already.
I have a service appt next week.

 

[EnergyVampire]

Service appt confirmed the hvbjb has failed. Waiting on replacement part.
Supposedly one week.
So two replacements with less than 4000 miles on the odometer. ?

 

[cbcasas]

Service appt confirmed the hvbjb has failed. Waiting on replacement part.
Supposedly one week.
So two replacements with less than 4000 miles on the odometer. ?

I wonder if it’s something else frying the HVBJB since it’s already failed twice.. on a brand new car nonetheless.

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