Certain Ford Fusion PHEV vehicles may experience damage to their Battery Energy Control Module (BECM) due to excessive voltage and current flow. This issue can lead to a loss of motive power and pose safety risks such as the possibility of a crash or a localized fire around the BECM. Ford is currently working on a fix for this safety issue.
Problem was first discovered in July 2022, when Ford’s Trend and Early Warning Support (TEWS) team alerted the Critical Concern Review Group (CCRG) about five fire reports involving 2019 Fusion PHEV vehicles equipped with 30Ah high voltage batteries. These fires occurred while the vehicles were at dealerships during a replacement BECM service to address various issues like voltage sense Diagnostic Trouble Codes (DTCs), check engine light, no start, or loss of motive power concerns. Ford’s High Voltage Battery Systems Team conducted an analysis and determined that the fires originated from the BECM. Further examination by the supplier revealed that the Current Interrupt Device (CID) had been activated in the high voltage battery cells of the affected units, though the reason behind this activation remains unknown. Due to the rate and severity of the concern, Ford’s CCRG initiated an investigation.
In February 2023, Ford published a Technical Service Bulletin (TSB) that advises replacing the high voltage battery if vehicles come in for service with one or more voltage sense DTCs, instead of just replacing the BECM. This measure aims to address the underlying issue and prevent further damage.
While a permanent remedy is under development, Ford urges owners not to charge their vehicles until the remedy is implemented. To ensure owners are aware of the safety risk, interim letters have been sent to them as of July 14, 2023. Second letters will follow once the remedy becomes available. This recall is identified as 23S33 by Ford, and the NHTSA campaign number is 23V-440.