Brad Clayton Posted April 27, 2011 Share Posted April 27, 2011 This is an '05 Escape that had some cooling fan issues in the battery pack. High voltage traction battery cooling fan replacement is a straight forward and relatively easy repair that can be done by techs in the dealership. Ford requires the tech to be “certified” to do some repairs and not to do other repairs. If you can read the shop manual and all its warnings, your shop has the gloves, then I would say you are qualified to do this repair at least on the customer’s dime. The intake duct on the left needs to be removed and the interlock on the right needs to be placed in the shipping position. This “kills” the battery. Fold the rear seats down and unplug the small connector on the driver’s side and unbolt the large connector. There is a plate that covers the high voltage connector, unbolt it and then release the latch and unplug the connector (just like newer PCM latch connectors). Eyebolts work great for removing these batteries. I am too lazy to make some, so I just bolt two chains up. One across the front of the batt. and one from the center lifting attachment to the middle of the rear chain. Remove the bolts holding the batt. to the floor. Out she comes. Keep the chains tight to prevent hitting the headliner with the picker. Safety first! Remove both top covers. Air flow (shown in green) comes thru the vent in the left side window, into the fan ducts (fans under duct pointed out in red) and then across battery packs. The duct work is removed and laid to the front, the connectors are disconnected. Fans are then removed. Reassemble in reverse order and install new felt wrap around the connectors and new zipties where old ones had to be cut off for fan replacement. And that be that, if one was inclined to do so, this could be done in the vehicle with some short cuts and prying. The only drawback to short cutting any batt. repairs involves certain death! Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted April 27, 2011 Share Posted April 27, 2011 Very nice pics. I can't say I've ever worked on a hybrid before, it's about the only thing I'm not certified to work on, I'd like to leave it that way. Quote Link to comment Share on other sites More sharing options...
Brad Clayton Posted April 27, 2011 Author Share Posted April 27, 2011 Thank you. I would have to say that the Escape was a wasted effort in the hybrid world. I would not recommend one if out of warranty for sure. The electrical system is way out of control in the pricing department. Starter motor (transmission): $8000. Alternator (dc to dc convertor): $2000. HVTB: 10 grand! We can't even make the call on batt replacements. We have to upload all the data from the car to the mother ship and then an engineer makes a decision. No matter how cut and dry the problem is, it's just too much for me and the dealer to shoulder if I am wrong. Had a great one come in a couple of years ago. Now keep in mind this customer bought a Hybrid Escape for fuel savings. He brings truck in with complaint of vehicle engine never shuts off to go into hybrid mode. I check it out and find out some electronics in the battery portion are bad and it thinks the battery is overheating. So not only is the engine running all the time but it's running to keep the air conditioning on to try and cool an overheating battery. It's about 20 degrees outside and the battery is not overheating. Great for fuel mileage! Quote Link to comment Share on other sites More sharing options...
lmorris Posted April 27, 2011 Share Posted April 27, 2011 Brad, your shop is WAY to bright. I would have to where sunglasses all the time. Quote Link to comment Share on other sites More sharing options...
mchan68 Posted April 27, 2011 Share Posted April 27, 2011 Brad, your shop is WAY to bright. I would have to where sunglasses all the time.I'll take working at Brad's shop ANYTIME. I prefer working in a shop that is well lit as opposed to a dungeon. I just need to find a U.S. woman that will marry me, to make it legal for me to live and work in the U.S. Quote Link to comment Share on other sites More sharing options...
lmorris Posted April 27, 2011 Share Posted April 27, 2011 Originally Posted By: lmorris Brad, your shop is WAY to bright. I would have to where sunglasses all the time. I'll take working at Brad's shop ANYTIME. I prefer working in a shop that is well lit as opposed to a dungeon. I just need to find a U.S. woman that will marry me, to make it legal for me to live and work in the U.S. Been used to working in a dimly lit old shop for over 15 years. Our new shop, coming soon, will hopefully look like Brad's. Quote Link to comment Share on other sites More sharing options...
mrbudge Posted April 27, 2011 Share Posted April 27, 2011 Google Azure Dynamics, they do hybrid conversions on Utilimaster vans built on a Econoline chassis, as well as the electric Transit Connect. There is a huge electric motor they sourced from a crane winch under these things behind the trans to drive it in electric mode, and a huge belt driven starter/generator under the motor to start the gas motor when demanded. Plus you got a hv traction battery, electric power steering, electric climate control, ..... Sounds like a lot of effort for what? But I got the training so I get to work on them. Quote Link to comment Share on other sites More sharing options...
Alex Bruene Posted May 5, 2011 Share Posted May 5, 2011 I started my Azure training a few weeks ago. I had an FSE come by today to show me the ropes a little and teach me how to use the diagnostic software. Looks like fun. I love a new challenge! Check it out www.azdtec.com Quote Link to comment Share on other sites More sharing options...
mrbudge Posted May 7, 2011 Share Posted May 7, 2011 Yes, challenge, good word for it. Trouble is you forget alot if there are not enough of them around to keep you busy. Are you doing the balance hybrid? Quote Link to comment Share on other sites More sharing options...
Alex Bruene Posted May 11, 2011 Share Posted May 11, 2011 I'm doing the Balance, and training on the Transit Connect. There are a lot of Balance Hybrids on the road in my area. Fed-Ex, Purolator, City of Toronto, IKEA and a few more, and only 3 certified repair facilities in the Greater Toronto Area(I think). The technical support is fantastic. They live connect to my lap-top and (help) diagnose it from a few different locations, and can (usually) have an FSE on-site within a day or two. The thing about them that kind of bothers me is that they don't have enough safety systems in place with the high-voltage system. Don't get me wrong, they're safe if you follow the directions, wear your gloves and check voltages anywhere you're not sure... But, unlike the Escape, there are components and cables that can be (easily) accessed without removing the master disconnect that will still be live... So, it's not as idiot proof as the Escape system (I've never worked on a Fusion, so I don't know how they are). Quote Link to comment Share on other sites More sharing options...
Alex Bruene Posted May 11, 2011 Share Posted May 11, 2011 BTW, I like the picture of Brad (I think) standing there with the "Shepherd's Hook" in hand. They say that is the only thing that stands between a closed casket or open casket funeral! Quote Link to comment Share on other sites More sharing options...
Brad Clayton Posted May 11, 2011 Author Share Posted May 11, 2011 I haven't worked on a hybrid in a few years, you should have seen the scavenger hunt that ensued whilst trying to find that damn thing. Quote Link to comment Share on other sites More sharing options...
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