22B39 – No-Start Condition – 2022 Ford Maverick

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ATTACHMENT III PAGE 1 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 CERTAIN 2022 MODEL YEAR MAVERICK VEHICLES EQUIPPED WITH A 2.5L FULL HYBRID ELECTRIC VEHICLE POWERTRAIN — HARNESS LAYOVER SERVICE PROCEDURE 1. De-energize the high voltage system. Follow Workshop Manual (WSM) procedures in Section 414-03. 2. Disconnect the battery. Follow WSM procedures in Section 414-01. NOTICE: Before disconnecting the high voltage battery electrical connector, the electrical connector must be cleaned with a nylon brush and free of debris. Blow any dirt or debris from the electrical connector with compressed air before disconnecting or component damage may occur. WARNING: High voltage electrical connectors may require unique methods to be disconnected. If not properly disconnected, component damage may occur. 3. Clean the high voltage battery electrical connector with a nylon brush. Blow any dirt or debris from the electrical connector with compressed air. 4. Disconnect the high voltage battery electrical connector from the Direct Current/Direct Current (DC/DC) Converter Control Module. See Figure 1. NOTE: Refer to WSM Section 414-03 (High Voltage Battery, Mounting and Cables, General Procedures, High Voltage Connector Disconnect and Connect). 5. Detach the retainer and position the wire harness aside. See Figure 1. FIGURE 1 2239A x3 1 3 2 ATTACHMENT III PAGE 2 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 6. Release the tabs and battery junction box cover. See Figure 2. FIGURE 2 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239B x6 7. Disconnect the battery junction box electrical connectors. See Figure 3. FIGURE 3 STUD FOR MISSING NUT STUD FOR STUD FOR MISSING NUT 2239C ATTACHMENT III PAGE 3 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 8. Release the wire guide from the battery junction box. See Figure 4. FIGURE 4 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239D 9. Release the tabs and remove the power distribution box from the bracket. See Figure 5. FIGURE 5 STUD FOR MISSING NUT STUD FOR MISSING NUT 2239E x4 ATTACHMENT III PAGE 4 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 10. Remove the power cable terminal cover. See Figure 6. FIGURE 6 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239F 11. Remove the nut. See Figure 7. Torque: 106 lb. in (12 Nm) FIGURE 7 STUD FOR MISSING NUT STUD FOR MISSING NUT 2239G 1 ATTACHMENT III PAGE 5 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 12. Disconnect the electrical connector and position aside the wire. See Figure 8. FIGURE 8 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239H 13. Release the wire guide from the battery junction box. See Figure 9. FIGURE 9 STUD FOR MISSING NUT STUD FOR STUD FOR MISSING NUT 2239J ATTACHMENT III PAGE 6 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 14. Remove the power cable terminal cover. See Figure 10. FIGURE 10 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239K 15. Remove the nut and position aside the power cable. See Figure 11. Torque: 106 lb.in (12 Nm) FIGURE 11 STUD FOR MISSING NUT STUD FOR MISSING NUT 2239L ATTACHMENT III PAGE 7 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 16. Remove the bolt and washer. See Figure 12. Torque: 83 lb. in (10.5 Nm) Remove the battery junction box bracket retainers. See Figure 12. FIGURE 12 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239M x2 17. Remove Left Hand (LH) Lower B Pillar. Follow WSM procedures in Section 501-05. 18. Remove the Rear Floor Storage Bin. Follow WSM procedures in Section 501-05. 19. Access the clutch port from the drivers side, under the Instrument Panel. See Figure 13. FIGURE 13 STUD FOR 2239N CLUTCH PORT ATTACHMENT III PAGE 8 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 20. Remove and discard the grommet. Insert the new wire harness, short side, into this port until it is stopped by the rubber grommet that is installed on the wire harness. See Figure 14. FIGURE 14 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239O RUBBER GROMMET See Figure 15 below for the full routing path of the harness. FIGURE 15 STUD FOR MISSING NUT STUD FOR MISSING NUT 2239AA ATTACHMENT III PAGE 9 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 21. Route the front portion of the harness through the engine bay as shown in Figure 16. New harness will follow the same path as the old harness. NOTE: Battery Junction Box and other items have been removed for clarity. FIGURE 16 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239P 22. Secure wire harness to the DC/DC Converter Module stud bolts., with the 2 push pin retainers that are installed on the harness. See Figure 17 FIGURE 17 STUD FOR MISSING NUT 2239X CONVERTER ATTACHMENT III PAGE 10 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 24. Continue to route wire harness through the door pillar area, moving towards the rear cargo area. See Figure 19. NOTICE: Ensure to place a tie strap on the new harness to keep it from touching the airbag connector. FIGURE 19 2239R AIRBAG CONNECTOR 23. From inside the vehicle route the harness through the pillar areas. See Figure 18. NOTE: Place a tie strap at each piece of blue tape found throughout the new harness. NOTE: It may be necessary to open the harness bundle shield before routing the harness. FIGURE 18 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239Q HARNESS BUNDLE SHIELD ATTACHMENT III PAGE 11 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 26. Route harness underneath the shield. Follow the path until the harness can be routed down along the Rear Floor Storage area. See Figure 21. NOTE: Make sure to lay out the harness across the Rear Floor Storage area and then apply the adhesive tie straps. FIGURE 21 2239S ADHESIVE TIE STRAPS 25. Position the carpet aside. See Figure 20. FIGURE 20 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239V ATTACHMENT III PAGE 12 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 27. Route harness as shown in Figure 22, moving towards the battery in the Rear Floor Storage area. NOTE: Continue to secure harness with the adhesive tie straps. FIGURE 22 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239T Front of Vehicle ADHESIVE TIE STRAPS 28. Install the protective caps while routing the harness. See Figure 23. FIGURE 23 STUD FOR MISSING NUT STUD FOR 2239BB PROTECTIVE CAPS ATTACHMENT III PAGE 13 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 30. Cut terminal end off of the old harness. Add Dual Wall Heat Shrink tubing to cover the open end of the wire and secure with tape. Using a zip tie, attach old harness to new harness. See Figure 25. NOTE: Pinch end of Heat Shrink to ensure that it is properly secured. FIGURE 25 STUD FOR MISSING NUT STUD FOR 2239CC 29. Disconnect the old harness from the positive cable. See Figure 24. FIGURE 24 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239W ATTACHMENT III PAGE 14 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 31. Route harness, as shown in Figure 26, making sure to secure the end to the battery, in place of the old harness. Torque: 93 lb.in (10.5 Nm) NOTE: Be sure to secure the harness with the attached adhesive tie strap as in previous steps, as well as the edge biter clips. FIGURE 26 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239U EDGE BITER CLIPS 32. Under the hood cut terminal end off of the old harness. Add Dual Wall Heat Shrink tubing to cover the open end of the wire and secure with tape. Secure to harness. See Figure 27. NOTE: Pinch end of Heat Shrink to ensure that it is properly secured. FIGURE 27 2239DD DC/DC CONVERTER ATTACHMENT III PAGE 15 OF 15 CUSTOMER SATISFACTION PROGRAM 22B39-S1 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 06/2023 33. If there is any excess wire harness left, secure using zip ties underneath the dash area. See Figure 28. FIGURE 28 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 2239EE 35. To reassemble vehicle, reverse steps 1-18. IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information. 34. Secure the new harness to the terminal. Torque: 106 lb.in (12 Nm) FIGURE 29 1 STUD FOR MISSING NUT STUD FOR MISSING NUT 2239FF  Copyright 2023 Ford Motor Company Stacy L. Balzer Ford Motor Company Operating Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan 48121 Ford Customer Service Division June 23, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: RECOMMENDED NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Customer Satisfaction Program 22B39 – Supplement #1 Certain 2022 Maverick HEVs Maverick No-start Condition REF: RECOMMENDED NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Customer Satisfaction Program 22B39 Dated June 8, 2023 NEW! REASON FOR THIS SUPPLEMENT • Labor operation 22B39B was miscalculated and should be 2.2 hours instead of 3.7 hours as listed. PROGRAM TERMS This program will be in effect through June 30, 2024. There is no mileage limit for this program. URGENCY / EXPIRATION DATE This Customer Satisfaction Program has an expiration date of June 30, 2024, to encourage dealers and customers to have this service performed as soon as possible. We recommend dealers utilize their FSA VIN Lists’ names and address to contact customers with affected vehicles. This will help minimize the number of vehicles that may experience a no-start condition, which requires a more extensive repair. FSA VIN Lists were available on June 8, 2023. AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates Maverick 2022 Hermosillo 26-Jul-2021 through 13-May-2022 US population of affected vehicles: 21,513. Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS PROGRAM In some of the affected vehicles, a no crank/no start condition may occur. This may be due to a loose or detached eyelet solder connection C1617E in the battery cable assembly at the battery junction box. SERVICE ACTION Before demonstrating or delivering any new in-stock vehicles involved in this program, dealers are to install a new 12V battery cable overlay and disable the current battery cable. This service must be performed on all affected vehicles at no charge to the vehicle owner.  Copyright 2023 Ford Motor Company OWNER NOTIFICATION MAILING SCHEDULE Owner letters are expected to be mailed the week of June 19, 2023. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter. ATTACHMENTS Attachment I: Administrative Information Attachment II: Labor Allowances and Parts Ordering Information Attachment III: Technical Information Attachment IV: Mobile Service Repair Assessment Owner Notification QUESTIONS & ASSISTANCE For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician System (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab. Sincerely, Stacy L. Balzer  Copyright 2023 Ford Motor Company ATTACHMENT I Page 1 of 3 RECOMMENDED NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Customer Satisfaction Program 22B39 – Supplement #1 Certain 2022 Maverick HEVs Maverick No-start condition MOBILE SERVICE REPAIR ASSESSMENT LEVEL All repairs in this program have the following assessment level. – Not Mobile Service Capable OASIS ACTIVATION OASIS was activated on June 8, 2023. FSA VIN LISTS ACTIVATION FSA VIN Lists have been available through https://web.fsavinlists.dealerconnection.com since June 8, 2023. Owner names and addresses will be available by July 7, 2023. NOTE: Your FSA VIN Lists 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 service action. SOLD VEHICLES • Owners of affected vehicles will be directed to dealers for repairs. • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. • Correct other affected vehicles identified in OASIS which are brought to your dealership. • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.  Copyright 2023 Ford Motor Company ATTACHMENT I Page 2 of 3 RECOMMENDED NEW VEHICLE RECOMMENDED DEMONSTRATION / DELIVERY HOLD Customer Satisfaction Program 22B39 – Supplement #1 Certain 2022 Maverick HEVs Maverick No-start condition STOCK VEHICLES • Correct all affected units in your new vehicle inventory before delivery. • Use OASIS to identify any affected vehicles in your used vehicle inventory. TITLE BRANDED / SALVAGED VEHICLES • Affected title-branded and salvaged vehicles are eligible for this service action. OWNER REFUNDS • Refunds are not approved for this program. RENTAL VEHICLES • Rental vehicles are not approved for this program. TOWING • If towing is required, dealers are authorized to claim up to a maximum value of $250 to provide towing services for this program. PICK-UP AND DELIVERY- Participating Dealers Dealers participating in the Remote Experience Program: • Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details. • All customers affected by this program have the option of complimentary Vehicle Pick-up & Delivery service. ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS) Additional repairs identified as necessary to complete the FSA should be managed as follows: • For related damage and access time requirements, refer to the Warranty and Policy Manual / Section 6 – Ford & Lincoln Program Policies / General Information & Special Circumstances for FSAs / Related Damage. • For vehicles within new vehicle bumper-to-bumper warranty coverage, no SSSC approval is required, although related damage must be on a separate repair line with the “Related Damage” radio button checked. o Ford vehicles – 3 years or 36,000 miles • For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval Request to the SSSC Web Contact Site before completing the repair.  Copyright 2023 Ford Motor Company ATTACHMENT I Page 3 of 3 RECOMMENDED NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Customer Satisfaction Program 22B39 – Supplement #1 Certain 2022 Maverick HEVs Maverick No-start condition CLAIMS PREPARATION AND SUBMISSION • Claim Entry: Enter claims using Dealer Management System (DMS) or One Warranty Solution (OWS) online. o When entering claims:  Claim type 31: Field Service Action  Sub Code: 22B39  Customer Concern Code (CCC): C27  Condition Code (CC): X4  Causal Part Number: 14290, Quantity 0 o For additional claims preparation and submission information, refer to the Recall and Customer Satisfaction Program (CSP) Repairs in the OWS User Guide. • Related Damage/Additional labor and/or parts: Must be claimed as Related Damage on a separate repair line from the FSA with the same claim type and subcode as described in Claim Entry above. IMPORTANT: Click the Related Damage Indicator radio button. • Pickup & Delivery: o Dealers participating in the Remote Experience Program –  Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details. • Provision for Locally Obtained Supplies: Includes additional tie straps for securing the wire harness further. Submit on the same line as the repair. o Program Code: 22B39 o Misc. Expense: OTHER o Misc. Expense: Claim up to $5.00 (up to $255 total for Misc. Expense: Other) • Provision for Towing: Dealers are authorized to claim up to a maximum value of $250 to provide towing services for completing this program. Submit on the same line as the repair. o Program Code: 22B39 o Misc. Expense: OTHER o Misc. Expense: Claim up to $250.00 (up to $255 total for Misc. Expense: Other)  Copyright 2023 Ford Motor Company ATTACHMENT II Page 1 of 2 RECOMMENDED NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Customer Satisfaction Program 22B39 – Supplement #1 Certain 2022 Maverick HEVs Maverick No-start condition NEW! LABOR ALLOWANCES Description Labor Operation Labor Time Confirm VIN and install replacement 12V battery cable 22B39B 2.2 Hours PARTS REQUIREMENTS / ORDERING INFORMATION Part Number Description Order Quantity Claim Quantity NZ6Z-14300-D Wire harness-overlay 1 1 W716053-S451 Interior Side Trim Clip As required W710338-S403 Right Floor Storage Bin Clips As required HU5Z-14A163-C Tie Strap 11 11 Order your parts requirements through normal order processing channels. To guarantee the shortest delivery time, an emergency order for parts must be placed. DEALER PRICE For the latest prices, refer to DOES II. EXCESS STOCK RETURN The excess stock returned for credit must have been purchased from Ford Customer Service Division by Policy Procedure Bulletin 4000.  Copyright 2023 Ford Motor Company ATTACHMENT II Page 2 of 2 RECOMMENDED NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Customer Satisfaction Program 22B39 – Supplement #1 Certain 2022 Maverick HEVs Maverick No-start condition REPLACED FSA PARTS INSPECTION AND SIGN OFF Effective March 1st, 2021, all parts replaced as part of an FSA repair with a repair order open date of March 1st, 2021, or later must be inspected and signed off on the repair order by a member of your dealer’s fixed operations management team or an employee the task has been delegated to. If the task is to be delegated to a non-management employee, the employee needs to be someone other than the technician who completed the repair and needs to understand the importance of completing this task consistently and accurately. • All parts replaced as part of an FSA repair should be returned to the parts department following the Warranty Parts Retention and Return Policies. • Inspect the replaced parts to verify the FSA repair was completed. • If the FSA repair is found to be complete, the designated employee signs the repair order line or parts return stamp area (electronic or hand signed) for the FSA repair indicating the parts were inspected and validated to have been replaced. • After the parts have been inspected, they should be handled based on the guidance in the parts status report in the Online Warranty System (Hold, Return, CORE, Scrap, etc.). • This process is subject to review during warranty audits for FSA repairs with a repair order open date of March 1st, 2021, or later. Any eligible FSA claims requiring parts replacement found not to have been inspected and signed off during a warranty audit will be subject to chargeback and consideration for enrollment into the Dealer Incomplete Recall Repair Process. Note: Other approvals (electronic or handwritten) for add-on repair lines, dealer-owned vehicle repairs, and repeat repairs do not qualify as FSA parts inspection approvals. The post-repair FSA parts inspection process (electronic or handwritten) is independent of other warranty approval requirements. The approval by the designated employee implies that the FSA parts were found to be replaced and must be able to be identified on the Repair Order. If multiple FSAs require approval on a single Repair Order, each applicable occurrence will require individual post-repair approval by the designated employee.

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