MACS Monthly Newsletter - 2022 - MAR3

Ford Escape. Drawing power from the high voltage
battery, this unit uses High Voltage DC from the
traction battery and drops it down to normal 12-volt
system charging voltage.
A few preventable situations can cause this unit
to fail. If the 12-volt battery has failed, the lack of
" reserve " or " buffer " the battery provides can spike
the DC/DC converter. If not remedied, the DC/DC
converter can fail.
Notice it is liquid cooled. Failure of this cooling
system can cause overheat and damage the DC/DC
converter.
The main ground bolts to the chassis on the horizontal
inner fender just behind the passenger headlamp
(Figure 2) next to the washer fill extension.
Salt, slush, and water pool in this area which encourages
corrosion of the numerous grounds, which
are bolted to the body. This is common in areas using
salt and/or brine on their roads during winter
weather. As with all electronics, poor grounding can
cause hard faults or " phantom " symptoms.
High voltage battery failure
IT IS HIGHLY RECOMMENDED THAT ANY DIAGNOSIS
OR REPAIRS TO THE HIGH VOLTAGE SYSTEM
OF A HYBRID OR EV ONLY BE PERFORMED
BY TRAINED, QUALIFIED TECHNICIANS USING
PROPER PPE, SERVICE INFORMATION, EQUIPMENT
AND SERVICE PROCEDURES.
Many think a Hybrid or EV with the longevity to
require a high voltage battery replacement is at the
end of its service life. Sure, some may be ready for
the scrap yard, but a vast majority of these vehicles
can continue giving reliable service if the battery
problem is addressed. Often, a used HV battery
will find its way into these vehicles to extend its life.
Some shops may repair the battery, but this requires
proper training, is usually a stopgap measure, and
the vehicle may return for the same issue in the notso-distant
future. If the customer has maintained the
vehicle at a very high level, that owner may opt for
a new and very expensive OE battery. Reman batteries
are also available, however many shops have
experienced quality issues.
Another option involves converting the original
Figure 2: 2007 Ford Escape DC/DC Converter Chassis Ground.
NiMH battery to Lithium. This option is just entering
the marketplace, is proving to be economically
sound and will bring the original battery pack back
Figure 3: DR. Prius App HV Battery Monitor.
March 2022
3
MACS Service Reports
Mike Bailey
Mike Bailey

MACS Monthly Newsletter - 2022

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