Tag Archives: electrical short

Ford Fusion PHEV Battery Problem
Risk Of Stall Or Fire

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Ford Fusion with smoke from trunk

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.

Toyota and Lexus Airbag Problem

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AirbagToyota and Lexus have announced that they will be reaching out to owners of specific vehicle models due to a critical problem related to the electrical connection inside the steering column. This issue has the potential to disable the driver’s side airbag, leading to non-compliance with Federal Motor Vehicle Safety Standards for Occupant Crash Protection.

The problem first came to Toyota’s attention in May 2023 when they were contacted by the spiral cable assembly supplier. The supplier informed Toyota about an ongoing investigation into the manufacturing process, which revealed contamination in the washing station for specific spiral cable components. As a consequence, a poor welding condition could occur between the Flexible Flat Cable (FFC) and the bus bar, which affects connectivity to various controls on the steering wheel. Extensive testing conducted by the supplier between late-May and late-June indicated that the FFC might detach from the bus bar at the weak weld connection area.

As per the defect report, the steering column assembly in the affected vehicles contains electrical connections to the driver’s airbag module housed within a spiral cable assembly, including the FFC. In cases where the FFC is inadequately welded to the spiral cable’s bus bar, there is a risk of the FFC separating, resulting in one or more open circuits linked through the FFC. This separation specifically impacts the circuit responsible for connecting the driver’s airbag module. If connectivity is lost, the SRS warning light will activate, and the driver’s airbag may be deactivated, failing to deploy in a crash scenario that necessitates its activation. Consequently, this raises the likelihood of driver injury in the event of a crash.

 

The vehicles affected include:

2023-2024 Lexus NX Hybrid
2023-2024 Lexus NX250
2023-2024 Lexus NX350
2023 Lexus RX Hybrid
2023 Lexus RX350
2023 Lexus RX500H
2023 Toyota Corolla
2023 Toyota Corolla Cross
2023 Toyota Corolla Cross Hybrid
2023 Toyota Highlander
2023 Toyota Highlander Hybrid
2023 Toyota Tacoma

Dealers will inspect and replace the spiral cable assembly as necessary. Toyota’s number for this recall is 23TA08, Lexus’ number for this recall is 23LA02 and the NHTSA campaign number is 23V-480.

Ford F-150 BEV Tail Lights Flicker

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Ford will be contacting the owners of certain 2022-2023 Ford F-150 Battery Electric Vehicles (BEVs) due to a problem that may cause inoperative or flickering back-up lights. This issue came to the attention of Ford’s Critical Concern Review Group (CCRG) in March 2023, following reports of moisture in the rear light bar of select F-150 BEV Platinum and Lariat vehicles from the 2022 and 2023 model years. These vehicles feature a rear light bar that spans the tailgate and houses the supplemental tail lamp and reverse lamp functions. Upon further investigation, Ford discovered an increased rate of warranty reports citing moisture in the rear light bar, which consequently resulted in certain claims of malfunctioning or flickering rear supplemental tail lamps and reverse lamps.

Upon examining the returned parts, Ford observed the presence of water droplets or condensation within the lamp, indicating micro cracks in the outer lens of the light bar. Testing conducted on the parts retrieved from the field revealed that over half of them had either inoperative or flickering supplemental tail lamps and/or reverse lamps. The investigation by the CCRG pinpointed the cause of stress on the light bar to be static and dynamic loading during the assembly plant fit process, which involves aligning the tailgate and surrounding components. Additionally, extreme tailgate surface loading in temperatures below -40 Celsius was also identified as a factor. The forces exerted on the light bar and its housing result in stress being transferred to the lens, potentially leading to the development of micro cracks.

To address this issue, owners who receive notices will be required to visit their dealerships to have the rear light bar replaced. Ford has assigned the recall number 23S30 to this specific recall, while the NHTSA campaign number is 23V-418.

In situations where vehicle owners encounter persistent issues with their newly purchased vehicles, such as the problems described above, they may be protected by lemon laws. Lemon laws vary by jurisdiction but are generally designed to provide legal recourse to consumers who unknowingly purchase vehicles with substantial defects that affect their safety, value, or use. These laws typically require manufacturers to either replace the defective vehicle or refund the purchase price if the vehicle cannot be adequately repaired within a reasonable number of attempts. If you suspect that your vehicle is a lemon, it is advisable to familiarize yourself with the lemon law provisions in your jurisdiction and consult with a legal professional to understand your rights and options for resolution.

Brake Pressure Switch Short May Cause Fire In Chevy Trucks

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General Motors. LLC (GM) has decided that a problem exists in certain 2019-2023 Chevrolet 4500HD, 5500HD, and 6500HD medium-duty trucks. The brake pressure sensor assembly could leak brake fluid into the brake pressure switch and cause an electrical short circuit.

GM opened an investigation in August 2022 following reports of a vehicle fire on a 2019 Chevrolet Silverado medium-duty truck. As part of that investigation, GM reviewed field data potentially related to the problem and warranty returned brake pressure sensors.

While a series of tests failed to duplicate the condition, in January, a warranty-returned sensor and harness were identified as exhibiting signs of heat damage. This part was subjected to more detailed analysis, including X-ray scans and a chemistry laboratory analysis. The results from these analyses revealed the presence of brake fluid past the diaphragm seal, into the brake pressure switch, and through the actual wire harness into the pump’s fuse circuit. An inspection of the returned components also revealed delamination of the corrosion-inhibiting sealant, which allowed slow seepage of the brake fluid past the diaphragm seal.

According to the defect report, a zinc-nickel plating and sealant used to inhibit corrosion within the pressure sensor assembly may cause delamination of the sealant which results in small fragments of sealer underneath the diaphragm during assembly which allows brake fluid to slowly seep past the seal and into the pressure switch. The brake fluid may seep into the sensor’s electrical components and short the brake pressure switch and the associated fuse. If brake fluid shorts the brake pressure switch and the fuse, the circuit can generate enough heat and could result in a fire. An under-hood fire may occur when the vehicle is off and possibly unattended.

Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will replace the master cylinder pressure sensor and inspect the wire harness. If the harness is damaged, it will be replaced as well. Interim letters notifying owners of the safety risk are expected to be mailed on May 29, 2023. Second letters will be mailed once the remedy is available. GM’s number for this recall is N222375270 and the NHTSA campaign number is 23V-266.

Chevy Express & GMC Savana HVAC Circuit May Overheat

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General Motors (GM) is one of the largest automobile manufacturers in the world, with a reputation for producing reliable and safe vehicles. However, like all automakers, GM occasionally identifies issues with its vehicles that need to be addressed to ensure the safety of its customers. Recently, GM identified a problem in certain 2003-2023 Chevrolet Express Cutaway and 2003-2023 GMC Savana Cutaway incomplete vehicles. These vehicles are equipped with wiring for an optional rear heating, ventilation, and air-conditioning (HVAC) system.

According to the defect report, these vehicles are equipped with an unused circuit that a final-stage manufacturer may elect to use to install an optional rear HVAC system. While this circuit is not typically used, if the final-stage manufacturer leaves the circuit’s connectors or cut wires unsealed, where exposure to moisture or contamination may, over time, cause corrosion. In rare cases, this corrosion could result in a high current draw through the circuit at the vehicles’ lower left side B-pillar. If left unaddressed, the problem could cause excessive heat in the circuit that could result in a fire.

To address this problem, GM began a product investigation in December 2022, after receiving reports of two alleged fire incidents involving a 2013 and a 2014 Chevrolet Express Cutaway incomplete vehicles. The company’s investigators analyzed inspection reports from the two subject vehicles and retrieved and analyzed field data for all Express Cutaway and GMC Savana Cutaway vehicles sold for model years 2005 through 2023, comprising approximately 167,000 units. Analysis of the field data, including legal claims, identified a total of eight potentially related complaints, six of which alleged fires.

On March 30, 2023, GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall. While the company is not aware of any accidents or injuries associated with this condition, it is taking this action to ensure the safety of its customers.

Owners of the affected vehicles will receive notices with instructions to return to their dealers to have the rear HVAC blower motor circuits at the left side B-pillar properly sealed. The recall is identified by GMC’s number N222386050 and the NHTSA campaign number is 23V-247.

Electrical Short In Battery Of Kia Soul EVs

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Kia will be contacting owners of certain 2015-2019 Kia Soul EVs about a problem that could result in a short circuit in the high voltage battery pack and a potential vehicle fire.

Kia first became aware of the problem in May 2022 when they received reports of smoke from the battery vents located under the passenger seat on a 2017 Kia Soul EV. Kia records showed that the vehicle’s high-voltage battery had been previously replaced under warranty. In October Kia received a second report, involving a 2018 Soul EV. The customer reported the smell of smoke just before the vehicle stalled. Kia performed CT scans and a tear-down analysis for both vehicles but the results were inconclusive due to thermal damage and water intrusion from fire suppression.

As Kia investigated the first two reports they received a third customer complaint of popping noises and smoke coming from the cup holders of a 2018 Soul EV in Hawaii. Kia and the battery supplier inspect vehicle #3 and performed a tear down analysis which found the heat damage was limited to the battery case assembly. The preliminary investigation results were inconclusive and the battery was shipped to the manufacturer for further analysis.

According to the defect report, an electrical short between the anode and cathode of the battery cells can occur with the high-voltage battery pack assembly case. The cause of the electrical short circuit is unknown but believed to be caused by abnormally excessive precipitate within the battery cells.

Although the cause of the electrical short circuit is unknown, Kia has decided to recall all 2018-2019MY Soul EV vehicles equipped with an E400 battery and certain 2015-2017MY Soul EV vehicles that had the high voltage battery replaced under warranty with E400 battery.

Dealers will update the battery management system software with new software that will illuminate the EV warning light, limit charging capacity, and reduce vehicle power if an abnormal voltage is detected. If this occurs, the battery will be replaced. Owner notification letters are expected to be mailed on May 26, 2023. Kia’s number for this recall is SC267 and the NHTSA campaign number is 23V-218.

There have been three (3) thermal incidents limited to the battery case assembly with no injuries, no crashes, and no fatalities.

Is Your Volkswagen ID.4 A Lemon?

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The Volkswagen ID.4 is a popular electric vehicle that has been making waves in the automotive industry since its release in 2021. However, like any other vehicle, the ID.4 has not been immune to problems, complaints, and recalls.

One of the most significant problems reported by ID.4 owners is related to the vehicle’s software. There have been multiple complaints of the software malfunctioning, resulting in issues such as loss of power, sudden deceleration, and even complete shutdown of the vehicle. These issues have led to multiple recalls of the ID.4, with Volkswagen issuing software updates to address the problem.

Another complaint reported by ID.4 owners is related to the vehicle’s charging capabilities. There have been complaints about the charging process being slow or inconsistent, with some reports that the vehicle fails to charge altogether. While this issue has not led to any recalls, it is something that Volkswagen needs to address to ensure that the ID.4 remains a competitive electric vehicle option.

There have also been several complaints regarding the ID.4’s braking system. Some drivers have reported that the brakes are unresponsive, while others have complained about excessive brake wear. These issues have not resulted in any recalls, but they are cause for concern and something that Volkswagen needs to address to ensure the safety of its drivers.

In addition to these issues, there have been a few recalls associated with the Volkswagen ID.4. The most recent recall involves certain 2023 ID4 rear-wheel drive vehicles. The 12-Volt battery charging cable may contact the steering column shaft and cause the cable insulation to wear, possibly resulting in a short circuit. As a precaution, owners of affected vehicles are advised to park outside and away from structures and other vehicles due to the potential risk of a vehicle fire.

In conclusion, while the Volkswagen ID.4 is a promising electric vehicle option, it has had its fair share of problems and complaints. From issues with the software to problems with the charging and braking systems, there are areas where Volkswagen needs to improve the vehicle. However, it is reassuring to see that Volkswagen has been proactive in addressing these issues, with recalls and software updates aimed at improving the driving experience and ensuring the safety of its drivers.

External Coolant Pump Could Short Circuit And Cause A Vehicle Fire

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Automobile manufacturers Porsche and Bentley Motors will be contacting the owners of certain 2017-2021 model vehicles because of a problem with the external coolant pump in the climate control system of their vehicles.

Porsche became aware of this problem at the end of December 2022, when they were contacted by their coolant pump manufacturer about a potential malfunction of the electric external coolant pump used in the climate control system. An investigation was opened and Porsche reviewed whether there were any possible common influences that could have contributed to the problem. (e.g. Extreme Temperatures, A Corrosive Medium, Special Driving/Customer Behavior, etc.) In January, Porsche determined a safety defect existed and decided to recall the subject vehicles. During this time, Porsche informed Bentley of their investigation because certain Continental GT and GTC vehicles were manufactured with the same pump.

The vehicles affected include:

2020 Bentley Continental GT
2020 Bentley Continental GTC
2017-2021 Porsche Panamera
2017-2021 Porsche Panamera 4
2017-2021 Porsche Panamera GTS
2017-2021 Porsche Panamera Turbo

According to the defect report, some 2017-2021 Porsche Panemera and 2020 Bentley Continental vehicles may have been manufactured with an electric climate control coolant pump that could experience humidity ingress. The humidity could cause a short circuit and, in some instances, thermal damage to the external coolant pump. In rare circumstances, the thermal damage to the harness could progress into a fire.

On the affected vehicles, vehicle occupants may notice an issue with the Climate Control system or reduced performance when using the Residual Heat function. (This allows the vehicle to be heated after the ignition has been switched off, using the remaining heat in a warm engine). On vehicles fitted with a W12 engine, an Engine Management Light could also illuminate.

Dealers will replace the external coolant pump and will inspect and replace the plug-in connection, as necessary.
Porsche’s number for this recall is APA1and the NHTSA campaign number is 23V-033
Bentley’s number for this recall is RE23/02 (RC67) and the NHTSA campaign number is 23V-034.