Mach-Lee

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Note: This TSB is written by me, not Ford. I've seen this issue in a dozen vehicles now.

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Issue: The user may experience a "Charge station fault" error and a flashing red ring indicator on the charge port 30 seconds after plugging in a Level 1 or Level 2 charger (J1772 plug). A P0D56:24 code will be set in the SOBDM. On some vehicles, a 12V drain may also occur after this fault is set until the plug is removed. If the user does not address the charge station fault and leaves the plug in, the 12V battery may drain in the next several hours, generating additional errors and/or starting issues. This issue is caused by operator error or a dimensionally incorrect J1772 that does not fully insert and latch into the charging port. NOTE: This is issue often associated with Grizzl-E brand chargers.

Resolution: Advise the user to always ensure the the J1772 plug is fully inserted until the latch clicks, and verify a blue indicator is shown on the charge port before walking away. If the J1772 plug is not easily to push in and latch, it may be dimensionally incorrect and defective. Advise the user to replace the EVSE cord. The charge port locking pin should also be inspected for damage per TSB 22-2345.

Tip: If this issue occurs, you must fully unplug and replug to clear the fault and resume charging!

Explanation: The J1772 handle contains an internal switch (S3) that is opened when the release button is pressed. If the plug is not fully inserted into the charge port, the latch will be lifted up on the ramp which prevents the S3 switch from closing (the release button won't come up fully). The car reads the status of this switch through the plug and sets a P0D56:24 code after 30 seconds if the S3 switch still hasn't closed (no charging will occur). On some vehicles (due to bad software?) the setting of this charge fault will cause the vehicle to stay awake and drain the 12V battery until the plug is removed. Many people will plug in and walk away without verifying the status lights, and will miss the error message that comes 30 seconds after plugging in. As mentioned above I've seen this issue happen primarily with Grizzl-E chargers, it seems they may have a dimension tolerance issue with their J1772 plugs that makes them a very tight fit, so this issue is much more likely to occur.

Suggestion: Ford, change the timing on this error from 30 seconds to 3 seconds so the user sees it before they walk away. Maybe add a honk in case they are walking away and there is a problem with the J1772 connection. Also change your fault handling (if you haven't yet) so the car goes to sleep while the charge error is active.

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billc58

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I can confirm that this is an issue. I have a Grizzl-E charger and often I have to wiggle the connection or unplug and plug in again to avoid the issue. I wait until I see blue lights before I walk away.
 

BalsaDust

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When I first started using my Grizzl-e I was getting errors and realized I wasn't hearing the "Click" of a full connection. Now I always make sure when inserting the connector I hear the click ans the charge display circle actually goes blue.
The original issue only happened to me twice before I figured the problem out, and now almost six months in it seems like the connector has "Worn-In" and clicks in easily every time.

Tony
 

markboris

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On my ChargePoint I needed a longer cord so I replaced their 23' with a 40'. The new connector was a bit stiff the first few times but as Tony said above, it has "worn in" and been working great ever since.
 

PMDGator

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Interesting. I've had my Grizzl E as long as my Mach E (Feb 2021) and I've never had this issue. I guess I'll pay more attention, but I suspect if it's fit just fine up to no it won't get worse.
 


ThatGuyLando

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I had a bad Lectron Vbox I had to return for a failure on the charger itself, but I remember the plug on it being super tight, good thing I didn't go with that brand I guess.
 

mkhuffman

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Interesting. I've had my Grizzl E as long as my Mach E (Feb 2021) and I've never had this issue. I guess I'll pay more attention, but I suspect if it's fit just fine up to no it won't get worse.
Same here - no issues with my Grizzl-e. But I use it as a travel charger so it isn't used daily.
 

Keeperofthe7keys

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Ah, the charger I happened to buy, good to be aware of. Interested in the subtle machining difference that resulted in their latch not locking properly easily.
 
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Mach-Lee

Mach-Lee

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Interesting. I've had my Grizzl E as long as my Mach E (Feb 2021) and I've never had this issue. I guess I'll pay more attention, but I suspect if it's fit just fine up to no it won't get worse.
Only some Grizzl-E’s have this issue, it may only be certain batches. I think they’ve changed cable suppliers at least once as well due to supply chain issues, this could be related to that.
 

Motomax

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Now that’s pretty funny, gotta love fords software skills.
my grizzl-e is a tight fit but not unreasonably. It’s pretty easy to see if it’s fully inserted. Also, just don’t hold the button down and you’ll hear a nice click…
 

cbcasas

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My first Grizzl E ordered in ~July had this issue. It would fault the car like crazy. I thought it was the car but the ford mobile charger worked like a charm. Got a replacement unit thru Grizzl E and it’s been good ever since
 

Logal727

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My grizz is a bit more snug than other brands but I’ve never had this issue for over a year. I always give a good push in till I hear it click though.
 

Aulander

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I experienced this fault once. After removing the plug I got an alert and the engine did not start, the display was on but the car was stuck. I called FordPass assistance and while I was explaining the issue my car started again after 10 min.

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