Relay / contactor clicking 5x sometimes when plugging in or starting car

[rvdbijl]

I've started noticing that when plugging in my AC charger or when starting the car, there is a clicking sound coming from under the hood - rapidly in succession, about 5 times. It doesn't always seem to happen, and I'm not sure if there is a correlation with cold weather.
I'm on the schedule for the HVJB recall (even though I've had no issues), but today after charging the car, I got the dreaded Stop Safely Now and Accessory Power warning. Looking around on the forum I found this: (27) Try This First - Powertrain Malfunction / High-Voltage Battery Warning / Service Vehicle Soon While Charging | MachEforum - Ford Mustang Mach-E News, Owners, Discussions, Community which seems to have fixed it for now. But getting a bit nervous about this behavior for sure...

Has anyone else noticed the chattering relay/contactor? Is this an indication of a future problem?

I also found some correlation between charging the car in the cold weather (it's ~20F here now) and charging faults at the END of the charge cycle. I have it set to charge to 90%, and when reaching the end of the charge cycle, I sometimes get the message "charger fault". I walk out and unplug / re-plug the charger and it's fine (it doesn't charge anymore, but it was done anyway). I never have these issues in the summer or when temps are >40-45F. I wonder if this is a charger issue (I have an Emporia EVSE) or a car issue .. Anyone run into that?

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[RickMachE]

Yes, many others have noticed it. It's the car, not the charger.

 

[Mach-Lee]

https://www.macheforum.com/site/threads/odd-clicking-sounds-when-plugging-in-the-car.33184/

 

[JSW]

Mine does this when it’s cold (and I just got the HVJB recall work done last week, so it’s not likely related). The sound makes me think the 12v is struggling.

I hope I’m wrong and just getting flashbacks to 1979 (my old Pontiac turned over soooo slow when it got cold, and I couldn’t afford a new battery)

 

[KevinS]

I'm more alarmed when the motor that opens the driver's door sounds like its really groaning (like the battery is low.)

 

[rvdbijl]

That’s good to know it’s not just me. I’ll mention it when my car goes in for the recall in a couple of weeks. I’m sure it won’t change anything, but maybe another data point for Ford …

 

[Mach-Lee]

That’s good to know it’s not just me. I’ll mention it when my car goes in for the recall in a couple of weeks. I’m sure it won’t change anything, but maybe another data point for Ford …

There's nothing wrong with it, so you don't need to mention it to your dealer. The clicking is normal/operating as designed in cold weather.

 

[rvdbijl]

There's nothing wrong with it, so you don't need to mention it to your dealer. The clicking is normal/operating as designed in cold weather.

I was more concerned about the charge faults every time the charge finishes when it’s cold. The clicking is fine now I’ve read more details about it.

 

[Mach-Lee]

I was more concerned about the charge faults every time the charge finishes when it’s cold. The clicking is fine now I’ve read more details about it.

Oh, get the firmware updated then.

 

[Logal727]

That’s good to know it’s not just me. I’ll mention it when my car goes in for the recall in a couple of weeks. I’m sure it won’t change anything, but maybe another data point for Ford …

lol way to get your car taken apart for no reason, the sounds are totally normal. You were better off coming here and getting the answer than wasting time at the dealership.

 

[areacode413]

I get the clicks on a ford evse. No charge faults. Did not think much of it myself.

 

[CHeil402]

This happened to me a few times last week when I plug in at work and had happened on occasion in the past. That charger has also caused the faults you mentioned, but they've always cleared without issue. I don't recall hearing that or having any issues when charging at home. Nothing enough to make me stop charging at work though.

 

[Ford Motor Company]

I've started noticing that when plugging in my AC charger or when starting the car, there is a clicking sound coming from under the hood - rapidly in succession, about 5 times. It doesn't always seem to happen, and I'm not sure if there is a correlation with cold weather.
I'm on the schedule for the HVJB recall (even though I've had no issues), but today after charging the car, I got the dreaded Stop Safely Now and Accessory Power warning. Looking around on the forum I found this: (27) Try This First - Powertrain Malfunction / High-Voltage Battery Warning / Service Vehicle Soon While Charging | MachEforum - Ford Mustang Mach-E News, Owners, Discussions, Community which seems to have fixed it for now. But getting a bit nervous about this behavior for sure...

Has anyone else noticed the chattering relay/contactor? Is this an indication of a future problem?

I also found some correlation between charging the car in the cold weather (it's ~20F here now) and charging faults at the END of the charge cycle. I have it set to charge to 90%, and when reaching the end of the charge cycle, I sometimes get the message "charger fault". I walk out and unplug / re-plug the charger and it's fine (it doesn't charge anymore, but it was done anyway). I never have these issues in the summer or when temps are >40-45F. I wonder if this is a charger issue (I have an Emporia EVSE) or a car issue .. Anyone run into that?

Hi there! Will you send us a message with your VIN and your local Ford dealer? I can look into things on my end.

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