Repeated Charge Faults

[ElectrifyCLT]

Interesting, I have the same issue with the Ford Power Brick. I have no idea when it started, as you mentioned the light just resets, but I did catch it this past weekend. I would assume it started in the past few weeks. I have noticed my "estimated complete" times to be delayed recently. However they have seemed to finish early each time. So maybe its freaking out cause my power delivery is not constant.

Ford Motor Company requested my info so I sent it to them today. I'm due for my 10k service and will be taking my car in as soon as my wife's car gets out from being repaired. Will be interesting to see what they say. Hopefully it's an easy fix of a bad power brick. With exception to the first month or so, I exclusively charge at home. I think I still have like 50kWh left on my free juice from EA.

I am curious what you find out. I too have caught the charger with this light arrangement, but never got any alerts or things that would otherwise indicate it wasn’t charging the car.

Keep us posted!

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[macchiaz-o]

Just odd that all the sudden it will longer stop the power delivery to the car when pushing that. I would assume DCFC would do the same.

Mine has always worked this way. I just tested it a few days ago while charging at home. The vehicle's unlock button by the charge inlet did the same thing that yours does.

The vehicle doesn't mechanically lock to J1772 couplers. The coupler latches on to the vehicle, though. The release button on your coupler stops the signal that keeps the charge session running and mechanically unlatches from the vehicle at the same time.

At a DCFC station, the vehicle locks onto the coupler and the vehicle's unlock button stops the charge session prior to mechanically unlocking the coupler.

My wife's car is in for autobody repairs all last week and looks to be all of next week. So I won't be able to get the MME in till she gets her car back.

Your dealer might be able to supply a loaner or rental. I'm a one car household so I always request that. Sometimes I have to pay for it but sometimes they offer to. Might be worth asking about it.

I checked the app, because I was curious what my SoC was going to be when we went house hunting. Car was showing like 5hrs to charge 8%. Went outside, orange light with pulsing blue..... Disconnected the car, light resets...

The car had only been on the charger maybe 15 minutes at best. Cord, Plug, Prongs, Power Brick, were all barely warm. They were by no means hot, and also not cold like I've felt in the past. So I'm starting to think my brick is bad. To me, that is a HUGE design fault.

Yeah sounds like the brick to me, too.

If charging stops, it just resets the lights. How would the end user ever know there is an issue?

Agreed. Not the best user experience.

Mine had the same orange light with pulsing blue back in May or June. But it was also quite warm near the bottom (towards the end of the brick with the cable that goes to the vehicle coupler). So I figured the thing isn't built ruggedly enough for Phoenix weather conditions. I never brought it into a dealer... I replaced it with a permanent wall mounted station and that's been working fine.

Good luck with getting it replaced. Please let us know how it goes. I hope they don't require you to drop off your vehicle if the only issue is the charge brick.

Given the vehicle situation, it sure would be nice if the dealer could swap charge bricks with you to verify this concern. I'm highly doubtful they're equipped to do that, though.

 

[Texas-E]

I've had my Mach-E since May 2021 and use a ChargePoint home charger exclusively (I tried an EA level 3 once). I have never had a charge fault until the last two times charging.

The lights around my charge port flashed red, but I can't recall if it did that happened when I pushed the button or if it was doing it when I walked up.

 

[Kabish]

Thanks Macchiaz-o I'll let everyone know what I find out.

The vehicle doesn't mechanically lock to J1772 couplers. The coupler latches on to the vehicle, though. The release button on your coupler stops the signal that keeps the charge session running and mechanically unlatches from the vehicle at the same time.

I think when I first joined the forum there was a lot of talk of pushing the button first to allow the car to know and prep for the charge to stop, so I just always did it. I find it interesting that your car is doing the same as mine. It 100% did not do that a few weeks ago. I would push the button, wait for its little animation then the lights to turn off and then unplug.

This morning I had the fault again, its almost daily now, and the car was still charging. I pushed the button and it was still pulling current. I held down the button on the Ford plug to see if that would signal a stop charge command and it had no effect that I could tell, it was still receiving current.

Doesn't seem to hurt anything, just an oddity that I noticed came along the same time as when I noticed the charging faults. ?

 

[aevans17]

I had the same issue with an after market charger where car would charge for 10-15 minutes then stop. Took my car to the dealership and they informed me that there were stored codes saying that there was too much heat/resistance on one of the pins. Seems like a failure with the charger I was using, specifically the J1772 getting water inside and rusting which cause increased resistance.

I sent the charger into the manufacturer as it is still under 1 year warranty and they said they found water inside the J1772 connector. Not sure how that can happen when the charger is supposed to be IP56 waterproof. I am curious if this is a common issue for all J1772 connectors.

The Ford charger brick is most likely water proof, but the J1772 connector is plastic with a seam down the middle. (Obviously made from 2 halves that are connected with screws.) I am not sure how water is kept out of the middle seam (other openings like the button) but seems like the plastic connector may allow water to get in.

Also the car is able to detect resistance on each pin and shuts off the charging session if the resistance is too high. This is likely to prevent excessive heat/fire/melting the J1772.

These are just my thoughts based on what I have seen and am not sure if this would be causing issues with the ford charger.

for those who got a new travel charger did Ford tell you what the failure was?

 

[macheavelli]

I have also been experiencing this off and on since Feb 11 (about 8 times) with a Job 2 Mach-e. I'll plug in the car in the evening for its scheduled charge (around midnight). It will then stop charging with a "Charge Fault". Using the Ford-provided charger with 14-50, professionally installed outlet.

It seems like some people have had success after a TSB was applied. I had the car in in Feb to see if they could fix the SiriusXM channels getting mixed up periodically, and they said nothing was outstanding on the car.

Is this TSB new-ish? Has anyone had this issue on a Job2?

 

[Ford Motor Company]

I have also been experiencing this off and on since Feb 11 (about 8 times) with a Job 2 Mach-e. I'll plug in the car in the evening for its scheduled charge (around midnight). It will then stop charging with a "Charge Fault". Using the Ford-provided charger with 14-50, professionally installed outlet.

It seems like some people have had success after a TSB was applied. I had the car in in Feb to see if they could fix the SiriusXM channels getting mixed up periodically, and they said nothing was outstanding on the car.

Is this TSB new-ish? Has anyone had this issue on a Job2?

Hello! Send us a private message with your VIN and the name and location of your local Ford dealer. I’d be happy to see what I can do to assist with this charge concern on your Mach-E. Thanks!

 

[Bongjovi]

ok. So I have been having this sane issue over the last few weeks.

vehicle was in at the dealership this past weekend and they claimed it was fixed, however when I went to charge after getting it back, same issue.

I have tried three separate level 2 chargers all with the same result so I know it is something with the car itself.

working with someone at Ford corporate who is on these forums to try and solve. No doubt she is trying.

I’ll update when we figure it out

My update

I had my car into dealer and they said the issue with charging was fixed, however four separate level 2 chargers later it continues.

I have done a ton of trouble shooting over the last few weeks using different chargers.

these chargers have all been tested with other types of vehicles with no issues reported. For certain it is something with the car.

while my car was at dealership it took a full charge overnight on their charger.

something is causing the car to stop charging. I have also been getting this alert when the charging stops

 

[hybrid2bev]

My update

I had my car into dealer and they said the issue with charging was fixed, however four separate level 2 chargers later it continues.

I have done a ton of trouble shooting over the last few weeks using different chargers.

these chargers have all been tested with other types of vehicles with no issues reported. For certain it is something with the car.

while my car was at dealership it took a full charge overnight on their charger.

something is causing the car to stop charging. I have also been getting this alert when the charging stops

When my car shows ‘Plugged in not charging’ it means it has fallen asleep. If I go out to the car and push the button to open the door then the car springs to life. Lots of clicks and clacks under the hood and it starts charging.

 

[Bongjovi]

When my car shows ‘Plugged in not charging’ it means it has fallen asleep. If I go out to the car and push the button to open the door then the car springs to life. Lots of clicks and clacks under the hood and it starts charging.

sadly, it doesn’t help my situation

even if it did it’s not a reasonable solution. car should charge without interruption

 

[Kagedog]

Hello! Send us a private message with your VIN and the name and location of your local Ford dealer. I’d be happy to see what I can do to assist with this charge concern on your Mach-E. Thanks!

I have been having the same issue with multiple Charge Faults only at home using the supplied Ford cable. The vehicle will start charging and then stop some time later in the middle of the night. I have also had the "Powertrain Malfunction/Reduced Power" notification with "Service Vehicle Soon" that is happening in other threads on this forum. I took the vehicle into the Ford Dealership where I bought it and after 4 days without my car (and no loaner) they said they couldn't find a problem and then it happened again a few weeks later. I tried a different dealership who wouldn't answer their phone and their online appointments were full so I went to the service department and wouldn't leave until I had an appointment. I am scheduled four weeks out for an appointment. This is clearly a recurring issue, can Ford provide guidance on what they plan to do about it?

 

[dmur726]

I'm mostly replying to I can track responses, in case a solution is found.

I have been having a problem since I got my car in October that it wouldn't stop charging at 90% as requested but always went to 100%. I was contacted here by the Ford rep who told me to bring it in to the dealer. I made an appointment, took it in, was told they needed to contact Ford corporate to figure out what was going on. Take the car home and they would contact me.

Three weeks later I called, and they told me the car was operating as it was supposed to. It has continued to charge to 100% about half of the time until last night. Last night it stopped at 24% (it was 18% when I started), with a charge fault. I took it to a fast charger and it charged just fine. I really can't afford to not know whether my car will be charged when I have to go to work, and I'm not confident Ford is looking for solutions given my last experience.

 

[Kdowdle]

3 DAYS CONFIDENT.

Hi! Is your car still charging no problem? We’re having the same issue, charge faults constantly and it’s super frustrating. We’ve already brought the car in twice, and it seems to help for a little bit, but as of the last week, the problem is back and worse than it’s ever been

 

[macheavelli]

It seems to be getting worse for me…tonight going on four charge faults:

 

[aevans17]

My guess is your Mach e is seeing high resistance on the charger and disabling the charge to prevent to much heat. If so you likely have water/corrosion in the J1772 connector of your charger.

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