2005-2007 EH/MH - CSP: Battery harness/module corrosion

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2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby Squishy - September 27th, 2008, 6:18 pm

(click on thumbnails to enlarge)

Dealer Letter
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Owner Letter
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Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated by August 22, 2007.

FSA VIN LIST ACTIVATED?
Yes, available through the website by August 22, 2007. Owner names and addresses will be available by September 5, 2007.

NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this program is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this field service action.

STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.

SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.

TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.

RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this service action performed on a timely basis.

ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center.

OWNER REFUNDS
Refunds are not authorized for this program.

RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.

CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect through August 22, 2009, or a maximum of 150,000 miles, whichever occurs first. If a vehicle already has accumulated more than 150,000 miles, this coverage will last through February 22, 2008.

Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Description
Labor Operation
Labor Time
Install a Service Harness in the HVTB and reprogram the BCM
07B48B
2.4 Hours

PARTS REQUIREMENTS / ORDERING INFORMATION
Part Number
Description
Quantity
7M6Z-14A303-B
Service Harness Assembly
1

Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Support Center or E-mailed.

DEALER PRICE
For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."

EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

Attachment III - Technical Information
OVERVIEW
This program involves installing a service harness in the High-Voltage Traction Battery (HVTB) and reprogramming the Battery Control Module (BCM).

Verify that the caution light is not ON before performing this repair. If caution light is ON, correct the condition before performing this program. Correcting a caution light resulting from any DTC other than P0A277 is NOT covered underthis program.

NOTE:
This service procedure must be performed by a technician that has completed the Hybrid Escape/Mariner New Model Classroom Training (course code 30N10T0).

SERVICE PROCEDURE
WARNING:
WHEN SERVICING THE HIGH-VOLTAGE SYSTEM, ESTABLISH A BUFFER ZONE PER THE SPECIFIED PROCEDURE IN THE WORKSHOP MANUAL. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

WARNING:
DEPOWER THE HIGH-VOLTAGE TRACTION BATTERY (HVTB) BEFORE CARRYING OUT ANY REMOVAL OR INSTALLATION PROCEDURES AFFECTING THE HIGH-VOLTAGE BATTERY SYSTEM. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

WARNING:
WEAR HIGH-VOLTAGE INSULATED SAFETY GLOVES AND A FACE SHIELD WHEN WORKING WITH HIGH-VOLTAGE BATTERIES OR CABLES. THE HIGH-VOLTAGE INSULATED SAFETY GLOVES SHOULD BE OF APPROPRIATE SAFETY AND PROTECTION RATING. INSPECT THE GLOVES BEFORE USE AND ALWAYS WEAR THEM WITH THE LEATHER OUTER GLOVE. ANY HOLE IN THE RUBBER INSULATING LOVE IS A POTENTIAL ENTRY POINT FOR HIGH-VOLTAGE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

WARNING:
DO NOT PUT WATER ON THE BATTERY BOX AND AVOID CONTACT OF THE BATTERY BOX WITH WATER WHILE WORKING ON THE HIGH VOLTAGE TRACTION BATTERY (HVTB). REMOVE ALL JEWELRY FROM FINGERS AND WRISTS PRIOR TO STARTING WORK ON THE HVTB. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

WARNING:
TURN OFF THE IGNITION SWITCH FOR A MINIMUM OF 5 MINUTES BEFORE REMOVING HIGH-VOLTAGE CABLES. HIGH-VOLTAGE CABLES, CONNECTORS AND WIRING ARE ORANGE IN COLOR. DO NOT TOUCH ORANGE-COLORED CABLES, CONNECTORS OR WIRING ONCE THE BATTERY BOX IS REMOVED. THE NOMINAL HIGH-VOLTAGE TRACTION BATTERY (HVTB) VOLTAGE IS 330 VOLTS DC. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH. SEE FIGURE 1 FOR LOCATIONS OF ORANGE HIGH-VOLTAGE CONNECTORS AND WIRES THAT SHOULD NOT BE TOUCHED.
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1. NOTE: There is a possibility of the isolator frames coming off from the battery box, do not swing or displace the battery box in any direction.

Remove the High-Voltage Traction Battery (HVTB) and place on a suitable work table that can support at least 100 kg (220 lb). Refer to the applicable model year Workshop Manual Section 414-03 for the removal procedure and warnings.

CAUTION:
Do not use power tools to remove the screws from the battery box. The screws thread into plastic bosses in the battery box. The use of power tools may damage the battery box bosses. Damage to the battery box bosses requires replacement of the battery, which is not covered by this program.

2. Remove the Allen-head bolt and Torx-head bolt from both sides of the front battery cover. See Figure 2.
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3. Remove the 2 Hex-head bolts securing the front side of the front battery cover. See Figure 3.
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4. Remove the 18 Torx screws from the front battery cover. See Figure 4.
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5. Remove the 15 Torx screws from the rear battery cover. See Figure 5.
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6. Remove the service disconnect plug and remove the front battery cover.

7. Reinstall the service disconnect plug in the SERVICE/SHIPPING position. See Figure 5.

8. Open the rear battery cover. The rear battery cover is connected to the battery box with 2 metal tethers, do not disconnect the tethers.

9. Cover the battery box using fender covers to make sure no debris falls into the battery box, leaving the lower RH area exposed. See Figure 6.
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10. Pull the connector, which is located near the service disconnect plug, out of the battery box and remove the insulation from the connector. Do not use any solvent to remove the insulation. See Figure 7.
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11. Slide out the lock cover (dark red part) and depress the release mechanism to unlock and disconnect the connector. Attach the service harness between the male and female parts of the original connectors. See Figure 8.
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12. Wrap the thin insulation provided around the original male side of the connector. See Figure 9.
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13. Run the service harness between the 2 bosses and guide the original female connector to the cavity next to the fan motor assembly. Attach the service harness to the boss using the provided tie strap and cut and remove the unused part of the strap. See Figure 10.
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14. Wrap the female side of the original connector and service harness together with the provided thicker insulation. Attach the tie strap provided around the insulation. Make sure that the connector is completely covered See Figure 11.
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15. Remove the fender covers.

16. Before installing the front and rear battery covers:
^ check for and remove any unused material in the battery box.
^ check that the harness does not protrude out of the battery box.
^ check that the seal is in the groove of the battery box.

17. Install the rear battery cover assembly but do not install the screws at this time.

18. Remove the service disconnect plug and install the front cover assembly, but do not install the screws at this time.

19. Reinstall the service disconnect plug in the SERVICE/SHIPPING position. See Figure 12.
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20. Before installing the screws, make sure that the battery seal is in the correct location and there is nothing protruding from the battery box.
CAUTION:
Do not use power tools to tighten the battery box screws. The screws thread into plastic bosses. The use of power tools may over-tighten the screws and damage the battery box bosses. Damage to the battery box bosses requires replacement of the battery, which is not covered by this program.

CAUTION:
For the finger tightening, manually align screw and tighten 2 threads or more to prevent crossthreading and then run them down until they just touch the battery cover.

21. Install the 15 Torx screws finger-tight in the rear battery cover, then tighten to 3 Nm (26 lb-in) in the sequence shown in Figure 13.
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22. Install and finger-tighten the 2 Torx-head bolts and 2 Allen-head bolts (2 each side) in the side of the battery box. Make sure that the tether bracket is correctly installed. Do not tighten the bolts at this time. See Figure 14.
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23. Install and finger-tighten the 2 Hex-head bolts securing the front side of the front battery cover. Do not tighten the bolts at this time. See Figure 15.
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24. Install the 18 Torx screws finger-tight in the front battery cover. Do not tighten the screws at this time. See Figure 16.
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25. Tighten 11 of the 18 Torx screws in the front battery cover to 5.2 Nm (46 lb-in) in the sequence shown in Figure 17.
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26. Tighten the remaining 7 Torx screws in the front battery cover to 3 Nm (26 lb-in) in the sequence shown in Figure 18.
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27. Tighten the Allen-head bolt on each side of the front battery cover to 20 Nm (15 lb-ft). See Figure 19.
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28. Tighten the Torx screw on each side of the front battery cover to 14 Nm (10 lb-ft). See Figure 19.

29. Tighten the 2 Hex-head bolts securing the front side of the front battery cover to 12 Nm (9 lb-ft). See Figure 20.
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30. Install the HVTB. Refer to the applicable model year workshop manual Section 414-03 for the installation procedure.

31. Reprogram the BCM using version B50 or higher on Integrated Diagnostic System (IDS).
The goggles, they do nothing!
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The Garage:
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Re: 2005-2007 EH/MH - RECALL: Battery harness/module (07B48)

Postby Dasha - September 27th, 2008, 7:13 pm

Thanks for the very detailed post, Squishy!! :thumb:
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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby GatorJ - September 15th, 2013, 4:42 pm

Now that the "quasi-recall" time period is over, if anyone is going to undertake this on their own, it is quite easy and, contrary to the instructions, most definitely does NOT require that the HVTB be removed from the vehicle. My mechanic friend and I did this in about 45 minutes today on my 2006.

The only specialized tool you need is a T-30 tamper resistant TORX socket.

Fortunately the harness is very near the service plug/fuse which is at the very rear of the right side of the front battery cover.

1. First, pull the service plug.

2. You need to remove all of the TORX bolts on both the front (closer to the rear seat) and rear (closer to the rear hatch) battery covers.

3. You also need to remove the black duct piece that channels air from the rear driver window to the battery pack assembly.

4. Tilt the rear seats forward and there are two 10mm bolts holding the front edge of the front battery cover that need to be removed

5. There are two large bolts on the sides of the front cover. We were able to reach those with channel locks.

6. You can then remove the rear battery cover. Careful, the edges are sharp and there is also a large gasket/weatherstripping you don't want to damage. As you start to pull it out, you'll see it has two grounding straps that prevent its complete removal. Just undo the one on the passenger side and you can swing it out of the way.

7. You will then see the target harness...85% exposed.

8. On the end closest to the rear of the vehicle it is covered by a 4" wide piece of foam insulation secured by a tie wrap. Cut the tie wrap, peel off the insulation and unplug the harness. Plug in the new harness connector, re wrap it with the supplied foam and re tie wrap it.

9. The other end has a much thinner foam insulation wrap and no tie wrap.

10. Also, pay attention to the position of the wires and how the harness is tie wrapped to the battery pack as you'll be cutting that one as well.

11. Both pieces of replacement foam and new tie wraps are included in the new harness kit, part number 7M6Z*14A303*B.

12. The hardest part is removing the foam insulation from the front connector. There was at least one bolt (possibly 2) of the sides of the front battery pack cover we couldn't remove. With all the other fasteners removed that I previously mentioned, I was able to pull the rear passenger side corner of the front battery cover up about 1.5" which was enough to allow my buddy enough room to peel off the foam, disconnect the connector, connect the new harness and re-wrap it with the new self-sticking foam.

13. Tie wrap the harness back down as it was before

14. Use compressed air to blow out any foam bits, etc. from the battery assembly.

15. Reassemble. Book time is 2.4 hours and we were easily done in 45 minutes. I took a few pictures that I'll add later.

NOTE: This is how we did it and I offer this to document that only. The battery pack is obviously high voltage and while I will feel bad if you electrocute yourself, your kid and/or your dog, I am not responsible. You are doing this at your own risk being fully advised of the risks in involved.

Connector by my thumb is the harder one to get to, other end is the one with THICK foam and two tie wraps:

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The bolts on the sides of the front cover you can grab from the sides with channel locks:

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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby shopsmith - September 16th, 2013, 5:56 am

Excellent info. If you have the Hybrid, make this fix. I wish I had known about it and I might have saved a couple hundred.
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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby GatorJ - September 16th, 2013, 10:28 am

This is the old harness:

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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby shopsmith - September 16th, 2013, 9:25 pm

Hybrid owners...he's on it. This and the other fixes keep you rolling. Hybrids are an "active ownership". I bet the taxis that go 400k miles are because guys got wise to all that's needed to keep them rolling. I'm doing the thermostat next just because it's 30 bucks now or hundreds later....that's if I keep this animal. If I do keep it, the PCV is in my future at some point.
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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby Jay2TheRescue - September 16th, 2013, 9:44 pm

My recommendation is if you do the thermostat, buy a new serpentine belt too. The thermostat is so much easier to service when you take the belt and belt tensioner off. You might as well just put a new belt back on it when you put it back together.
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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby shopsmith - September 17th, 2013, 6:56 pm

Yup, did the belt about 6 months ago. I'm with you.
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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby hbp112358 - October 1st, 2016, 10:05 pm

Would this also clear a P0562 Code? it's the only Code I have left now that I stripped the Pack apart and cleaned the contacts for the thermocouple connectors (the other connector next to the connector for this wiring harness).

I haven't owned it long enough to know if that code is just an informational code or not.

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Re: 2005-2007 EH/MH - CSP: Battery harness/module corrosion

Postby Hoka - September 12th, 2018, 6:46 am

I suspect that I need to replace this harness too on my 2005 Escape, but I cannot find the cable anywhere here in Holland and so far none of the US suppliers I contacted are willing to ship it to Holland.

Can anyone point me in the direction of someone who will ship to Holland, my local Ford dealer is not willing to help!

Also, is it essential to reprogram the computer after this procedure and who would be able to do that here?

Please help!
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