Second HVBJB Failure (New HVBJB)?

[LuckyKH4]

2022 GTPE. Purchased in May 2022, HVBJB failed in November 2022, replaced in December 2022 with the upgraded HVBJB. Today (10/10/23) I received "High-Voltage Battery Warning" and "Powertrain Malfunction/Reduced Power" along with max reduction in power bars. Dropped off at the dealer this evening, will update when I have more details and if it's a confirmed failure again.

I'm trying to identify whether anyone has had the new HVBJB fail but can't see to find any info on this. Has anyone seen this at all? I saw a recent post where someone had a second HVBJB failure but their original replacement was the old part.

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[AKgrampy]

2022 GTPE. Purchased in May 2022, HVBJB failed in November 2022, replaced in December 2022 with the upgraded HVBJB. Today (10/10/23) I received "High-Voltage Battery Warning" and "Powertrain Malfunction/Reduced Power" along with max reduction in power bars. Dropped off at the dealer this evening, will update when I have more details and if it's a confirmed failure again.

I'm trying to identify whether anyone has had the new HVBJB fail but can't see to find any info on this. Has anyone seen this at all? I saw a recent post where someone had a second HVBJB failure but their original replacement was the old part.

Yes, there have been a few failures of the new HVBJB reported and I believe one former owner had at least two new ones fail ( total or 4 replacements overall but he is the exception!) Not sure how many people have had a repeat failure such as yours though.

 

[Shayne]

Yes, there have been a few failures of the new HVBJB reported and I believe one former owner had at least two new ones fail ( total or 4 replacements overall but he is the exception!) Not sure how many people have had a repeat failure such as yours though.

Any solid numbers on that? Can you define a few?

The question if the original is any good has been answered if the revision is is the next question that needs to be answered. Since I have very few miles on mine and have gone through 2 originals I should be able to determine if my revision is any better within a year or 2.

Here is to hoping there is a revision to the revision out now that will save us from the 3rd time and a fourth HVJB.

Someone needs to cut a hole in the floor to make these accessible. It is like the 12V that also never needs to be charged or replaced.

 

[AKgrampy]

Any solid numbers on that? Can you define a few?

The question if the original is any good has been answered if the revision is is the next question that needs to be answered. Since I have very few miles on mine and have gone through 2 originals I should be able to determine if my revision is any better within a year or 2.

Here is to hoping there is a revision to the revision out now that will save us from the 3rd time and a fourth HVJB.

Someone needs to cut a hole in the floor to make these accessible. It is like the 12V that also never needs to be charged or replaced.

That is the problem. Some people have reported failures but no real follow up that it was in fact the HVBJB or was it a bad contactor like the original part. Perhaps the NHTSA investigation will give some data. The forum is just a subset of owners so no way to tell how many newer ones have failed. From reading though the majority are older parts but that may just be my perception. Personally I do not see how they can get something much more robust in the tight area where the HVBJB is situated without adding active cooling of some sort which would take a redesign. Or just a bigger unit with a better heat sink. Either way I am not sure much more can be done without a redesign but that is just my 2 cents.

 

[Shayne]

That is the problem. Some people have reported failures but no real follow up that it was in fact the HVBJB or was it a bad contactor like the original part. Perhaps the NHTSA investigation will give some data. The forum is just a subset of owners so no way to tell how many newer ones have failed. From reading though the majority are older parts but that may just be my perception. Personally I do not see how they can get something much more robust in the tight area where the HVBJB is situated without adding active cooling of some sort which would take a redesign. Or just a bigger unit with a better heat sink. Either way I am not sure much more can be done without a redesign but that is just my 2 cents.

If they come back with no form of confirmation I am not sure if it is then fact? May be just for the internet?

I think there are two types of failures on the originals; stuck open and stuck closed. Open kills the 12V (charge that and it works no problem) and welded shut will crease after awhile (I have heard; the software saved me and just drove it around). Problems with the spec/build of those connectors for me. I am hoping I have a decent fix this time and they know what they are doing and the revision is it.

 

[Maquis]

@heisnuts definitely had failure(s) of the latest design.

 

[AllenXS]

My first HVBJB replacement (with the first HVBJB model) wasn’t actually HVBJB failure. It was other parts but they replaced out of caution.
The new version has been good so far after 10 months

 

[Shayne]

@heisnuts definitely had failure(s) of the latest design.

Kind of hoping I am not that sort of nuts .

My first HVBJB replacement (with the first HVBJB model) wasn’t actually HVBJB failure. It was other parts but they replaced out of caution.
The new version has been good so far after 10 months

1st 04/18/22
2nd 09/07/23

You are not out of the woods yet

 

[Mach-E Mikey]

I have a late 22 Premium build. Just had mine fail after 16,000 miles. Estimated 2 weeks to replace.

 

[LuckyKH4]

I have a late 22 Premium build. Just had mine fail after 16,000 miles. Estimated 2 weeks to replace.

Thanks for the info. Not reassuring. I have 17k miles. I’m really hoping that I’m not replacing this thing every 8-9k miles

 

[LuckyKH4]

@heisnuts definitely had failure(s) of the latest design.

Thanks. After continued research, his is the only post I’ve seen on this.

 

[heisnuts]

Thanks. After continued research, his is the only post I’ve seen on this.

As most of you know, I am a very rare use case. Even so, I believe engineering is still working on the problem. I gave them a lot of data using a data tracker on my HVBJB torture routes. I would not be surprised if that data leads to a revised part and/or design in the future.

 

[LuckyKH4]

As most of you know, I am a very rare use case. Even so, I believe engineering is still working on the problem. I gave them a lot of data using a data tracker on my HVBJB torture routes. I would not be surprised if that data leads to a revised part and/or design in the future.

It’s probably premature because I don’t have confirmation yet (it’s with the dealer but I don’t know when they will diagnose), but I actually have two High Voltage Battery Warnings in Ford Pass concurrently now.

I’m definitely not putting the same pressure on the car as you described in your post; I probably WOT once a drive when I have the appropriate conditions, but not tons of hills and opportunities for repeat WOT.

I L3 charged on the first HVBJB one time and L3 charged probably 2 or 3 times on the new HVBJB.

So overall I’m really in no way pushing the limits of what the GTPE is spec’d for.

 

[shelnian]

As I indicated before, I don't believe Ford changed the HVBJB design, they just changed the factory testing of the contactors to ensure fewer defective contactors are installed. Assuming test is measuring voltage drop across the contactor at a high current over some period of time, based on the software update they installed as part of the recall.

 

[AKgrampy]

As I indicated before, I don't believe Ford changed the HVBJB design, they just changed the factory testing of the contactors to ensure fewer defective contactors are installed. Assuming test is measuring voltage drop across the contactor at a high current over some period of time, based on the software update they installed as part of the recall.

They did change the part number so you would think something changed. I do not believe the overall design changed either. Just better/beefier contactors. If you have seen one you can see there is not much space available for change. I just speculate that the HVBJB manufacturer now installs the most robust contactor that can fit into the existing space. I also read, not saying it is fact, that remanufactured HVBJB are being sent out as replacements so no matter what it could only be a component swap if that is a fact.

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