2016 Ford Focus Electric

16B02 – High Voltage Lower Battery Connector Corrosion – 2012-2016 Ford Focus Electric

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NHTSA ID Number: 10204984

Manufacturer Communication Number: 16B02C

Summary

Delivery Hold – Customer Satisfaction Program 16 B02 Certain 2012-2016 Model Years Focus Electric vehicles High voltage Lower battery connector corrosion.

 

2016 Ford Focus Electric
2016 Ford Focus Electric

 

PROGRAM TERMS  

This program will be in effect through May 31, 2017.  There is no mileage limit for this program.

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Focus Electric 2012-2016 Michigan September 15, 2011 through December 9, 2015

 

This Customer Satisfaction Program applies to vehicles originally sold in, or currently registered in the following states:

Connecticut Iowa Minnesota Ohio Wisconsin
Delaware Maine Missouri Pennsylvania
District of Columbia Maryland New Hampshire Rhode Island
Illinois Massachusetts New Jersey Vermont
Indiana Michigan New York West Virginia

 

REASON FOR THIS PROGRAM

In the affected vehicles, corrosion on the high voltage lower battery connector may cause deformation of the connector allowing water ingress.  Water ingress into the high voltage lower battery could result in a high voltage circuit isolation fault with a “Stop Safely Now” message displayed in the message center.  If this occurs, the vehicle may not restart once it has been shut off.

 

SERVICE ACTION

Before delivering any of the vehicles involved in this program, dealers are to remove the high voltage lower battery from the vehicle, clean and inspect the high voltage lower battery connector, apply corrosion protection, install a protective shield and reinstall the high voltage lower battery in the vehicle.  This service must be performed on all affected vehicles at no charge to the vehicle owner. NOTE:  The high voltage lower battery in some vehicles may require shipment to a specialized facility to complete repairs.

 

OWNER NOTIFICATION MAILING SCHEDULE

Due to capacity constraints to repair the high voltage lower battery, and to assist dealers in managing customer expectations, owners of affected vehicles will be notified in four separate mailings. Mailing will begin by March 28, 2016.  Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

 

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.

 

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.  

 

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

Dealers are pre-approved for up to 14 days for a comparable rental vehicle if the inspection results determine the high voltage lower battery must be shipped to Piston Group for repair.  Follow Extended Service Plan (ESP) guidelines for dollar amounts.  Rentals will only be reimbursed for the days the vehicle is at the dealership for battery repair.  Prior approval for more than 14 rental days is required from the SSSC via the SSSC Web Contact Site.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number Description Order Quantity
CM5Z-9916A315-A High Voltage Lower Battery Connector Shield 1
CM5Z-8A424-A Coolant Filter (only required if battery repaired) 1 as required
7703-W 16B02 - High Voltage Lower Battery Connector Corrosion - 2012-2016 Ford Focus Electric | small light Daubert NOX RUST (available in aerosol spray can)

(obtain from https://www.daubertchemical.com/store/productlist/corrosion-prevention/nox-rust-7703-w )

 1

Claim as

MISC OTHER

 

ATTACHMENT III

CERTAIN 2012-2016 MODEL YEAR FOCUS ELECTRIC VEHICLES — HIGH VOLTAGE LOWER BATTERY CONNECTOR CORROSION

 

OVERVIEW

In the affected vehicles, corrosion on the high voltage lower battery connector may cause deformation of the connector allowing water ingress. Water ingress into the high voltage lower battery could result in a high voltage circuit isolation fault with a “Stop Safely Now” message displayed in the message center. If this occurs, the vehicle may not restart once it has been shut off. Dealers are to remove the high voltage lower battery from the vehicle, clean and inspect the high voltage connector, apply corrosion protection, install a protective shield and reinstall the high voltage lower battery in the vehicle.

NOTE: The high voltage lower battery in some vehicles may require shipment to a specialized facility to complete repairs.

 

SERVICE PROCEDURE

High Voltage Lower Battery Removal and Connector Inspection – (All Vehicles) – Page 2.
Apply Corrosion Protection – (If No Connector Damage Present) – Page 5.
Battery Repair Process – (If Connector Damage Present) – Page 6.
High Voltage Lower Battery Connector Shield Installation – (All Vehicles) – Page 7.

WARNING: Service of the high voltage system on this vehicle is restricted to qualified personnel. The required qualifications vary by region. Always observe local laws and legislative directives regarding electric vehicle service. Failure to follow this instruction may result in serious personal injury or death.

WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a highvoltage symbol. Failure to follow these instructions may result in serious personal injury or death.

WARNING: Never install the service disconnect plug when a high-voltage service cover is removed. Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.

WARNING: Disconnect the 12 volt battery before servicing the direct current to alternating current (DC-AC) inverter or alternating current (AC) powerpoint to prevent the risk of high voltage shock. Failure to follow this instruction may result in serious personal injury.

 

High Voltage Lower Battery Removal and Connector Inspection (All Vehicles)

  1. Remove the high voltage lower battery. Please follow the Workshop Manual (WSM) procedures in Section 414-03A.
  2. Inspect the three connectors on the LH side of the high voltage lower battery for cracking.
    See Figures 1a and 1b.

    • Are cracks present on any of the three connector bodies?
      • YES – The high voltage lower battery must be shipped to Piston Group for repair.
        Proceed to Battery Repair Process on Page 6.
      • NO – Proceed to Step 3.

CRACKINGFIGURE 1a                         FIGURE 1b

 

  1. Apply tape (masking, electrical or duct) to the connector faces to protect the terminals and keep the connector housing clean. See Figure 2.

HIGH VOLTAGE CONNECTORSFIGURE 2

 

  1. Using a brass wire brush, throughly clean the areas surrounding the three high voltage connectors to aluminum plate mating surfaces. Using compressed air, clean the loose debris from the connectors. See Figures 3a and 3b.

WIRE ALUMINUM BRUSHFIGURE 3a                                                 FIGURE 3b

 

  1. Attempt to insert a 0.003 in. (0.076 mm) feeler gauge between the aluminum plate and the top and sides of the two smaller high voltage connectors and the sides of the large high voltage connector. See Figures 4a and 4b.
    • – Does the feeler gauge fit between the aluminum plate and the connectors at one or more of the locations indicated in Figure 4a?
      • YES – The high voltage lower battery must be shipped to Piston Group for repair.
        Proceed to Battery Repair Process on Page 6.
      • NO – Proceed to Step 6.

FEELER GAUGEFIGURE 4a                                                    FIGURE 4b

 

  1. Attempt to insert a 0.015 in. (0.380 mm) feeler gauge between the aluminum plate and the top and bottom of the large high voltage connector. See Figure 5.
    • Does the feeler gauge fit between the aluminum plate and the large high voltage connector?
      • YES – The high voltage lower battery must be shipped to Piston Group for repair.
        Proceed to Battery Repair Process on Page 6.
      • NO – Proceed to Apply Corrosion Protection below.

FEELER GAUGEFIGURE 5

 

Apply Corrosion Protection (If No Connector Damage Present)

  1. Ensure the tape is completely covering the connector faces. See Figure 6a.
  2. Spray Daubert NOX-RUST 7703-W generously around the perimeter of all three connector to aluminum plate mating surfaces. See Figure 6b.
    • Allow the corrosion protection to penetrate for a minimum of ten minutes.
  3. Apply a second coat of corrosion protection.
  4. Install the high voltage lower battery into the vehicle. Please follow the WSM procedures in Section 414-03A.
  5. Proceed to High Voltage Lower Battery Connector Shield Installation on Page 7.

connector facesFIGURE 6a                                                             FIGURE 6b

 

Battery Repair Process (If Connector Damage Present)

NOTE: The battery repair process must only be completed if directed in High Voltage Battery Removal and Connector Inspection steps 2, 5, or 6.

  1. Locate and record the high voltage lower battery serial number. See Figure 7.

NOTE: The battery serial number and battery connector inspection results will be required when submitting a Battery Repair Approval Request.

SERIAL NUMBERFIGURE 7

 

  1. Create a Special Service Support Center (SSSC) Battery Repair Approval Request via the SSSC Web Contact Site for battery repair approval and instructions. The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen.

NOTE: High Voltage Battery Shipping Instructions will be e-mailed or faxed from the SSSC when a battery repair is approved. Please provide a valid e-mail address (preferred) or fax number when
submitting a battery repair approval request.

  1. Once the repaired battery has been returned from Piston Group to the dealership, install the high voltage lower battery into the vehicle. Please follow the WSM procedures in section 414-03A.
  2. Proceed to High Voltage Lower Battery Connector Shield Installation on Page 7.

 

High Voltage Lower Battery Connector Shield Installation (All Vehicles)

  1. Remove the LH wheel and tire. Please follow the procedures in WSM Section 204-04A.
  2. Remove the LH rear fender well splash shield spring clip washer. See Figure 8.

SPRING CLIP WASHERFIGURE 8

 

  1. Remove the bolt thread rubber cap. See Figure 9.

BOLT THREAD RUBBER CAPFIGURE 9

 

  1. Remove the high voltage battery shield bolt and push pin. See Figure 10.

HIGH VOLTAGE BATTERY SHIELD BOLTFIGURE 10

 

  1. Position the top of the high voltage battery connector shield behind the LH rear brake hose and trailing arm. See Figure 11.

HIGH VOLTAGE BATTERY CONNECTOR SHIELDFIGURE 11

 

  1. Install the LH rear fender well splash shield spring clip washer. See Figure 12.

HIGH VOLTAGE BATTERY CONNECTOR SHIELDFIGURE 12

 

  1. Install the high voltage battery shield bolt and push pin. See Figure 13.
    • Tighten the high voltage battery shield bolt to 20 lb.ft (27 Nm).

HIGH VOLTAGE BATTERY SHIELD BOLTFIGURE 13

 

NOTE: The bolt thread rubber cap must be reinstalled. Failure to install the cap may result in parking brake cable damage.

  1. Install the bolt thread rubber cap. See Figure 9.
  2. Install the LH wheel and tire. Please follow the procedures in WSM Section 204-04A.

 

March 2016

Customer Satisfaction Program 16B02
Programa de satisfacción del cliente 16B02

 

Mr. John Sample
123 Main Street
Anywhere, USA 12345

 

Your Vehicle Identification Number (VIN):  12345678901234567

At Ford Motor Company, we are committed not only to building high quality, dependable products, but also to building a community of happy, satisfied customers. To demonstrate that commitment, we are providing a no-charge Customer Satisfaction Program for your vehicle with the VIN shown above.

Why are you  receiving this notice?

“Stop Safely Now”

“Stop Safely Now”

 On your vehicle, it may be possible for corrosion on the high voltage lower battery connector to cause deformation of the connector allowing water intrusion.  Water intrusion into the high voltage lower battery could result in a circuit isolation fault that will cause a “Stop Safely Now” message to display in the message center.  If this occurs, you may not be able to restart your vehicle after it has been shut off.
What will Ford and your dealer do? In the interest of customer satisfaction, Ford Motor Company has authorized your dealer to inspect the high voltage lower battery connector and service as required, and then install a protective shield free of charge (parts and labor) under the terms of this program.

This Customer Satisfaction Program will be in effect until May 31, 2017 regardless of mileage.  Coverage is automatically transferred to subsequent owners.
How long will it take? The time needed for this repair is usually less than one-half day.  However, depending on the condition of the high voltage lower battery connector, your dealer may need your vehicle for up to two weeks to complete repairs.
What should you do? Please call your dealer without delay and request a service date for Customer Satisfaction Program 16B02.  Provide your dealer with your VIN, which is provided above, and request that your dealer order parts to repair your vehicle.

If you do not already have a servicing dealer, you can access www.Fordowner.com for dealer addresses, maps, and driving instructions.

Ford Motor Company wants you to have this service action completed on your vehicle.  The vehicle owner is responsible for making arrangements to have the work completed.
Do you need a rental vehicle? If your dealer determines that the high voltage lower battery connector is damaged, your dealer is authorized to provide a rental vehicle for your personal transportation at no charge (except for fuel, insurance, and tax) while your vehicle is at the dealership for repairs.  Please see your dealer for guidelines and limitations.
What if you no longer own this vehicle? If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner.

You received this notice because our records, which are based primarily on state registration and title data, indicate that you are the current owner.
Can we assist you further? If you have difficulties getting your vehicle repaired promptly and without charge, please contact your dealership’s Service Manager for assistance.

RETAIL OWNERS:  If you have questions or concerns, please contact our Ford Customer Relationship Center at 1-866-436-7332 and one of our representatives will be happy to assist you.  If you wish to contact us through the Internet, our address is:  www.Fordowner.com.

For the hearing impaired call 1-800-232-5952 (TDD).  Representatives are available Monday through Friday:  8:00AM – 8:00PM (Eastern Time).

FLEET OWNERS:  If you have questions or concerns, please contact our

Fleet Customer Information Center at 1-800-34-FLEET, choose Option #3, and one of our representatives will be happy to assist you.  If you wish to contact us through the Internet, our address is:  www.fleet.ford.com.

Representatives are available Monday through Friday:  8:00AM – 8:00PM (Eastern Time).
Para asistencia en Español Visite nuestro sitio web para ver este anuncio en Español al siguiente dirección: https://es.owner.ford.com/tools/account/maintenance/recalls.html

Si necesita ayuda o tiene alguna pregunta, por favor llame al Centro de Relación con Clientes al 1-866-436-7332 y presione 2 para Español.

 

Thank you for your attention to this important matter.

Ford Customer Service Division

 

5 Affected Products

Vehicle

MAKE MODEL YEAR
FORD FOCUS ELECTRIC 2012-2016

 

1 Associated Document

Manufacturer Communications

Customer Satisfaction Program 16B02
March 22, 2016

https://www.nhtsa.gov/recalls?nhtsaId=10204984

MC-10204984-9999.pdf 1747.496KB

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NHTSA ID Number: 10074364

Manufacturer Communication Number: 16B02

Summary

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

 

1 Associated Document

Manufacturer Communications

Customer Satisfaction Program 16B02
March 22, 2016

https://www.nhtsa.gov/recalls?nhtsaId=10074364

MC-10074364-0699.pdf 1747.496KB

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MUSTART Level 2 EV Charger, 40 Amp, 240 Volt, 25ft Cable, Electric Vehicle Portable Charger Plug-in EV Charging Station with NEMA 14-50P, ETL Certificated
MUSTART Level 2 EV Charger, 40 Amp, 240 Volt, 25ft Cable, Electric Vehicle Portable Charger Plug-in EV Charging Station with NEMA 14-50P, ETL Certificated
  • FAST CHARGING SPEEDS: The MUSTART 40A level 2 EV charger which is more sturdy, contains more sensitive chips, higher protection level and better abrasion resistance, can charge your car up to 2.5X faster than the 16A level 2 EV charger. It is 5X faster than the 16A level 1 EV charger that most electric vehicles come with. (The actual working current it depends on your vehicle setting).
  • SUPER COMPATIBLE: Works with most electric vehicles in the United States , the EVSE is compatible with all plug-in EVs. *Tesla requires a SAE J1772 adapter.
  • Well-trusted Quality: Strictly pass UL-2594, ETL certificated. Lightening-proof, leakage, over-voltage, overheat and over-current protection. Whenever your Mustart EV chargers have any problem or anything simply not meeting your needs, please contact us. We provide a two-year warranty of our products from the date of your original order in our store.
  • CONVENIENT: Compact size with a total 25 feet charging cable for flexible installation and usability. All you need is just a 220 Volt or 240 Volt NEMA14-50 outlet to plug the charger into.
  • HIGH QUALITY: This portable charging station is made to last with durability and reliability. It is lightening-proof and has leakage, overvoltage, overheat and overcurrent protection, so you can safely charge your vehicle.
$279.00 Amazon Prime
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SaleBestseller No. 9
EVIQO Level 2 EV Charger - 48 Amp EV Charger Level 2, 240V Electric Vehicle Charging Stations, EV Level 2 Charger NEMA 14-50/Hardwire EVSE Level 2 Charger, 25' Cord Electric Car Charger Energy Star/UL
EVIQO Level 2 EV Charger - 48 Amp EV Charger Level 2, 240V Electric Vehicle Charging Stations, EV Level 2 Charger NEMA 14-50/Hardwire EVSE Level 2 Charger, 25' Cord Electric Car Charger Energy Star/UL
  • 9X FASTER: EVIQO is electric vehicle charger for home providing 38 m/h (40 amp ev charger by default) and 46 m/h if hardwired and set as a 48A EV charger. Max output for EV charging station level 2 is set with a dip switch. Adjustable current: 1A increment in EVIQO app. Stay EVIPOWER-ful with live 24/7 post-sale customer support.
  • SAFE, USA CERTIFIED: EVIQO electric car charger level 2 is UL compliant, Energy Star, ETL and FCC certified EV charging station with 3 years Manufacturer Warranty. EVIQO level 2 home ev charger is weatherproof. This EV car charger level 2 is suitable for use as an indoor/ outdoor EV charger. EVIQO EV wall charger level 2 meets NEMA 4 and IP66 protection standards.
  • SMART APP: EVIQO surveyed 1,800 EV owners to create EV home charger level 2 app. Set up to 3 schedules for cost savings during off-peak rates. Get smart tips and reminders, track power/costs live and monitor the charging history. Enjoy sleek intuitive interface of your electric car charger 240v. EVIQO level 2 car charger consistently enhances its firmware with remote OTA updates.
  • COMPATIBLE WITH ALL EVs: EVIPOWER electric car home charging stations are equipped with heavy duty rubberized SAE J1772 connector compatible with all EVs / PHEVs in NA: all Tesla models, Chevrolet Bolt, VW ID 4, Nissan Leaf, Polestar 2, Ford Mustang Mach-E, IONIQ 5/6, BMW i3, i4, iX, Mercedes EQS, Audi, Rav4, Jeep Wrangler 4xe level 2 charger (Tesla requires an adapter).
  • FIRST-IN-CLASS: EVIQO electric vehicle charging stations offer the MARKET'S LONGEST 37" input cable with a NEMA 14-50 plug along with a 25' EXTRA LONG output cable.
$479.00 −$30.00 $449.00 Amazon Prime
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Bestseller No. 10
Level 1+2 EV Charger, 16 Amp 120V or 240V, Portable Electric Vehicle Charger with 21Ft Charging Cable NEMA 6-20 Plug,Plug-in Home EV Charging Station for SAE J1772 EVs(Tesla Need Adapter)
Level 1+2 EV Charger, 16 Amp 120V or 240V, Portable Electric Vehicle Charger with 21Ft Charging Cable NEMA 6-20 Plug,Plug-in Home EV Charging Station for SAE J1772 EVs(Tesla Need Adapter)
  • 【High Compatibility EV Charger】LiftSun EV charger is compatible with electric vehicles that meet SAE J1772 standards. our EV charger comes with NEMA 5-15 and 6-20 plugs that make it workable for both level 1 & level 2. The portable electric vehicle charger has an 21FT cable, long enough for most driveways or garages.
  • 【Level 1+2 J1772 EV Charger】 Our EV charger cable is 4 times faster than a standard EV charger comes with your car under Level 2 charging mode. It has a power range of 95-265V, up to 16A for level 2, Enable you to charge quickly under Level 2 power supply.
  • 【Safety Guarantee Car Charger】This Level 1+2 EV charger weatherproof rating is IP66, controller IP54, CE certification, with lightning protection, leakage, grounding, low voltage, overvoltage, overcharge, overheating and overcurrent and other multiple protection.
  • 【Simple Designed EV Charger】The LifstSun EV Charger has LED indicator on the control box shows three different states: power, charge, and fault to help you identify the working status of EV charger and keep you informed of relevant charging information. If a fault is found, it will alert you and let you deal with the problem immediately.
  • 【Portable Car Charging Station】Our portable EV charger is lightweight designed and included storage bag to makes it easy to carry around and stay organized in your car, allowing you to charge anywhere, anytime, without having to find an EV charging station outside. We provide a durable NEMA 5-15P to 6-20R adapter, This EV charger can be carried directly in the car, always available, and can be charged anywhere there is a 120V or 240V socket.
$125.98 Amazon Prime
Buy on Amazon Price incl. tax, excl. shipping

Last update on 2024-06-21 / Affiliate links / Images from Amazon Product Advertising API

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