Thank you sir, for this humorous enlightenment that the modern import vehicles have not seen the need to improve on the Ford Motor Company's Designs from way back in 2005 (having been with the Ford company since the 80's as a tech.)
You are absolutely absolutely wonderful and genius sir. I absolutely admire you work. I wish I would have someone with me to teach me all this stuff. I absolutely love working on these electric cars and really need someone's help to learn about them. And you are doing this without asking anything in return. You are given knowledge for sake of nothing that's is just amazing. Just brilliant. Can't thank enough for these videos.
Professor John Kelly I have driven Ford Fusion Hybrid cars for eight years now and really like them and their reliability. It is so interesting to see the inner workings of these cars. Thank you so much for the great explanations and demonstrations and detail and I understand everything you say. I just follow your lectures religiously. Thanks again.
This video actually helped me diagnose my vehicle. I drive a 2015 Ford C-Max energi, and him showing the auxilary transmission pump helped me identify the connector I needed to clean up. If you also get a P0C2- code, check that connector! It might be loose or dirty
We purchased a Fusion Energi to go along with our Mitsubishi Outlander PHEV after the family learned the benefits of owing an EV - a full electric is a step too far given our poor public charging station network, but we only need to visit a gas station once per month now on average, sometimes longer. Both vehicles drive brilliantly, and ownership costs has dropped by $400 per month at the cost of $40 higher electric bills. Not a bad trade-off at all. Thanks again for the in-depth explanation of the less known Ford Hybrid powertrains.
Great video as always Professor JD. I remember years ago the first time hearing the word "stator" was being used on an amusement park ride and was the latest and greatest technology alternating the power to magnets on a track to make a roller coaster go and stop. Too cool!!
I'm only 17, but I really enjoy working on cars and getting my hands dirty. But I have never had any proper training on working on cars, I have just been learning as I go. And your channel has really helped me a lot in learning all about cars and how they work, and WHY they do what they do! I love your work and please keep it up, it helps me so much. Especially that older video you did on the manual transmission and how it works. Thanks a ton!
Very interesting, I have worked on some Honda and Toyota hybrids, but the wife's Fusions seemed to stop working. I had thought maybe the trans had gone bad (seems like the stator is not capable of making the car move). I did a code scan - could not believe that there were no codes in ANY of the systems. Except when you shut the car off it tells you how many EV miles and Regen miles and those are almost always 0 or very .2 almost nothing. So I figured I better start doing some digging and learn some before I make a 5 thousand dollar mistake on what maybe a bad connection. Thanks for the great video and all the info - will be watching more
Thank you John for educating me on how my 13 Fusion works. I did notice something strange. Those 2 large (orange) high voltage cables have connectors the look identical. They don't appear to be keyed in a way to prevent them from being swapped. Maybe they are but it's not noticeable on the camera. I'm a retired machinist from a large connector manufacturer, and that type of keying is extremely important.
I have not one but 2 2016 Ford C-Max Energi`s one brand new and one preowned with 12k miles. I love the cars and really enjoyed learning how the electrical operation works.
It's interesting to see a hybrid design convergence of the parallel motor generator for Ford, Toyota- GM, and Chrysler. This is the same for example with the internal combustion engine variable timing and direct injection and many more. The various manufacturers experimented with their proprietary design until the industry decided toward common design concept.
Incredible! Thanks so much for this terrifically insightful video. I’m the new owner of a 2020 Fusion Ti Energi, and I’m amazed to see how accessible you make this info. Keep it up!
Sir my respect and appreciation for this outstanding lecture 👏 👏 👏. I knew zero=0 about how this cars mix the electrical with the mechanical part. You practically opened my eyes on this! Thank you very much!
Thank you for this outstanding video. We are now on our second lease of a Ford C-Max Energi after 3 happy years with a 2015 SEL. Glad to have these videos. Never really understood the true theory of operation until watching this. Subscribed.
Thank you for the information. I want to put this system in a boat I’m building. I know I won’t get the regenerative power, but I’m okay with that issue. Will watch the rest of the videos to see why it wouldn’t work. Thanks, Chris
Hi Professor John, on a personal point, I trust you and yours are well . Thank you for your gentle but engaging presentation, could watch you all day. I first found you on the Honda CVT which was absolutely brilliant. Thanks again. Seasons' tidings to you and yours. Pete on the Isle of Wight.
I'd like to hear more about the big micro-chips that are the brains of these motor controllers. It seems to me these chips are the breakthrough technology that made these game changing transaxles possible
Reading up about Brushless DC motors can reveal a lot of the background... I have limited hobby-level experience with one chip by Texas Instruments, the C2000 which is a microcontroller (embedded CPU w/ built-in memory) whose CPU core is optimized for the kind of math required. You quickly get "into the weeds" reading about this stuff but here's a few articles to chomp on - www.ti.com/lit/an/bpra055/bpra055.pdf ... www.ti.com/lit/an/sprt703/sprt703.pdf ... the C2000 series processor I evaluated once - www.ti.com/product/tms320F28027 - You quickly realize that the same set of processor "skills" required to perform motor control are also relevant with digital power conversion, think not 3-phase inverter for an EV but also 3-phase or single-phase inversion for producing AC power for the grid from DC (e.g. solar+battery) sources as well.
Thank you for your great work! You’ve made most informative videos about hybrid transaxles here on RUclips. I haven’t yet seen anything close to this :)
Wye should be how its connected, all three hot wires are connected to one neutral, at least for a three phase AC stator. The other is a Delta which has 4 wires, three hot and one ground. Company I worked for used wye connection on our three phase 400 hz systems, but again these were AC inductance motors. So Im not sure with this setup. Our Stators looked exactly like those too, I use to make some of the coil windings myself, also the stator stacks, then they were sent out to be inserted. Women were better than men for inserting the coils. When the completed stators returned to us they were then impregnated with a 2 part epoxy in a vacuum chamber so there was no air in the stator windings. The wires are called magnet wire, the coating is extremely tough, that tranny couldn't get hot enough to melt that coating under normal operation. The wire itself is fully annealed. Enjoyed what I did and I thank you for an awesome video...
Great video, thank you. I've got a 2014 fusion hybrid and you have a wonderfully straightforward way of breaking down and explaining all the components. One small criticism ... I don't know exactly how the fusion inverter drives their stators but if it is like a typical VFD system I suspect your voltage explanation is a little off. Typically a 3 phase system like these motors are not really 2 on, one off so much as a staged change where one is voltage is always 1/3'd of the way ahead of it's brother, they lead each other around more than alternate.
Thanks for breaking this down. I've had two Fusion Energi models (13' & 19') and have found the design to be terribly durable so far. Since there is no torque converter, would it be just a fluid change and not a flush?
The power split system on my 2014 CMAX doesn't appear to be operating in tandem anymore. It used to be that over certain load levels both electric and gasoline motors would be working together then the electric motor would take over when the load was light. We just got hit by 34days worth of -40 degree celcius weather and upon the 3rd day I discovered the hybrid battery had dropped to near zero from full charge the night before. Since then when driving it's either full electric mode or gas only mode regardless of battery charge level and the two only work in tandem for very very brief periods maybe a few seconds at a time. I can hear the switching from inside the car. I don't know enough about the system to judge if prior operation was normal or if the current operation is normal and the cold weather had nothing to do with it. It's still under warranty 44000km. Fuel economy sucks too 33mpg (city) and that's with the ever optimistic digital readout, it's actually closer to 30mpg. Anyway, any ideas?
Most engine coolant temperature sensors register -40 degrees C when there is an electrical open circuit. The system may have been tricked into thinking there is a malfunction. The very cold weather will certainly affect the operation. I would have a Ford dealership check it for recalls, technical service bulletins, and any malfunctions that have not illuminated a check engine light. Best wishes.
@@WeberAuto I've an appointment set for this Monday we'll see, I actually really like this car and hope they get it all sorted. While the fuel economy is a bit disappointing for a hybrid i'm coming from a 7mpg truck so happy any which way. Thank you!
Thanks for all your hard work in producing these video's. This old boy is learning a whole lot. Looking forward to the detailed electrical system video (I live for that kind of stuff !!!)
Interesting how similar the Ford and Toyota designs are. I’ve heard the original Escape hybrid has one of the most bulletproof drivetrains ever made, and taxi services have consistently been able to pull half a million miles+ without trouble. It seems that the Achilles heel of the Toyota system has historically been the motor winding(s) burning out. Now that they’ve switched to the bar-wound stator assembly (like GM has been using for years), I have a feeling the P610 won’t have these issues. It looks like this will be a very good transaxle, so long as the heat exchanger is effective enough to cool the transmission fluid and prevent the ATF from cooking.
Ford did use the same transaxle manufacturer (Aisin) for the Escape Hybrid that Toyota uses, but Ford did its own research and discovered similar patents, so Ford and Toyota exchanged patent rights. Ford never copied Toyota ideas.
Thanks for your work, just fyi we’re about to trade in our 2017 C-Max energi with 340K miles for a lower mileage 2017 C-Max. Had to be a rideshare driver in 2017 after years as a taxi crown Vic driver. Kudos to Ford for the excellent vehicle and wish they had a 2022. The best vehicle ever and has never needed a brake job!!
@@beammeupscottsp7952 yes, trans fluid change was done twice and most recently was at 310k .. sad to say a large deer ended that vehicle just one week after we installed a new ford factory rebuilt engine. we’re now using Tesla model 3 with no issues after 33K miles and 5 months in service . TY
@@jamesmonroe8962 oh wow! I’ll make sure to change the trans fluid as soon as possible then, hate to hear about the accident but congrats the on the model 3, will go full ev but not until the fusion hybrid decides to give out. If there’s any other maintenance service you did please let me know!
Thank you for these videos, they are helping with my disgnosis of the common P0A7C on the 2010-2012 Fusion Hybrids. As of yet, I don't know of any solution, and Ford's TSBs seem ineffective. Pretty sure I've narrowed it down to the coil temperatures, which means I need to drain and fill the transaxle fluid (and measure how much is in mine).
Outstanding video Professor John. I have just bought a 2014 Lincoln MKZ 2.0L FWD Hybrid with The Hf-35 xCVT trans and it is leaking out about 3qt, but the car drives great. Because of the leak the Transfer-shaft assembly (EG9Z-7H348-A) bearing and cup should be shot, but those parts only cost US $410 right now. Is it possible to put a rebuilt used HF35 eCVT or even a newer Ford 2017-up HF45 eCVT and not have to reprogram the power transfer unit? The only cable that comes out of both trans are the hi-voltage drive/regen motors and the low-voltage data cables (that reads both motors temp and speeds). From what I have read; the HF35 has no brain or need for VIN programming itself. I ask because my locale Lincoln Dealer just quoted me US $10,000+ to replace the HF35, recalibrate the Lane-departure system, and realign the wheels. Since I was not born yesterday and value my family's treasure, I figured I would ask an expert. The car is beautiful and still drives it just need seals and bearings but no trans shop in or near Chicago will touch these eCVTs due to Ford's EV service equipment requirments (an anti-static bay). I have removed FWD trans and replace clutches before and I am thinking of removing and rebuilding my own trans because of inflated dealer costs. Any help you can provide would be much appreciated "for eductional info only... lol". Thank you for your time, sir. BTW: Can you do a trans removal video on the HF35 and HF45? That would be amazing.
I have been following the Lincoln vehicles from the mark series up to the 2016 model MKZ hybrid. Since the Ford fusion hybrid is built at the same plant in Hermosillo Mexico as the MKZ hybrid I believe they are both Same . I enjoy all your videos about this particular product I do on wiring diagrams two vehicles from 2014 through 2019 on the MKZ or a fusion they’re both the same book and the energy thank you very much you do a Netflix job regards
I know I'm late to the party on this one, but have you considered discussing how the HF35 needed to be redesigned in 2015 due to a known design flaw which caused very rapid bearing wear and potential failure/need to replace the transmission on many Fusion/C-Max hybrid cars. I would be interested to learn what they changed with the should-have-been-recalled-but-didn't design.
Is mercon LV petroleum driven? I used Molly to reduce the bearing friction and it did. Wonder about its effect on the windings coating. Also this time I wanna use DCT full synthetic Lv, fluid which is very close to mercon. Only thing I wonder about is the coatings on the windings.
thanks sir for sharing this information... how much the output voltage for the generator? and what is the input voltage of the motor?.. why they called it high voltage? is more than 2000 volts? how the brakes gives the high voltage?
Just bought a 2018 Fusion energi. I'm impressed. Everywhere I read it says it has a CVT. Looking at the gear train in this transmission I do not see a means of varying the ratio. Am I missing something?
It actually provides a variable gear ratio with underdrive ratios, direct drive, and overdrive ratios. It works just like the Toyota transaxles. See my video here for a better description ruclips.net/video/O61WihMRdjM/видео.html
Professor, could you please post an image of the fluid level port for the HF-35 that you mention at the 14:00 minute mark of this presentation; I just changed the Mercon LV on my 2013 CMax and want a better idea of a correct refill than just the replacement of fluid volume removed. Thank you for sharing this information.
Pause the video at ruclips.net/video/MZf_BUuW5Qg/видео.html The Fluid Level Check Plug has a yellow label and is shown in the bottom right of the screen. Thank you
Fantastic! Thank you for pointing that out, I had missed it on the first viewing; will share with another person who has a DIY fluid change video posted.
Hi. Can you please tell me, my friend and I cannot understand how the planetary unit works? Is there a ratchet or some kind of overrunning clutch? Or why, when the engine is off, the planetary gear itself with the traction motor rotates, but the engine does not? Through what mechanism is the torque transmitted from the engine to the main gear? If so, does it have a ratchet that has free play in one direction and does not have it in the other? Thanks for the video, very informative
I use a wheelchair and just bought a 2010 E450 hybrid . Having problems finding manuals or mechanical manuals for the Azure hybrid plus that battery. Any suggestions? I want to use this e450 cutaway limo wheelchair lift bus. I'm disabled Deaf Veteran: I'm so grateful for CAPTIONS! Thanks
18:33 actually half of the magnets are being pushed and the other half pulled. when it comes to magnets it's very confusing if you just look at their poles. if you look at the magnetic field lines actually it isn't pull or push but simply a rotational force
Thanks for your feedback. I was describing the operation on a very basic level and showing the relationship to the resolver cam positioning. Yes, it is more complex than what I was describing. Have a great day.
The Ford and Toyota hybrid transaxles are made by Aisin , a Japanese company which got its start during World War II. it has been wrongly reported that Ford merely license Toyota's design. In fact Toyota and Ford just agreed not to sue each other for patent infringement on hybrid transaxles so they do use the same basic design. The planetary gear set itself dates way back to at least the design of the Ford Model T.
@@aggressor9517 of all the failures... News... Articles.... Reports.... The 35 transaxle tech is toyota and ford based. Shared tech. The transaxle is actually quite robust and taxi fleets are getting 400k-600k miles on original gears and batteries.
Could you please answer a question for me, I have a 2019 Ford Fusion Hybrid, as I was going down a long hill the other day and the car started making a strange noise, sort of like the sound anti-lock brakes makes only not as bad. I noticed that the HVB was showing that it was maxed out with power, what happens when the HVB is maxed out but the dash symbol is showing that Regen braking is still charging, how does the system use up the over charge that's coming to the battery, is there some system to burn off that extra energy? As soon as I used some of the battery power it never made the noise again.
That’s likely the electronic brake booster if it sounds like the abs system when running in ev mode there isn’t an engine running to produce a vacuum for the brakes to instead they use an electronic pump that will run occasionally to give you boost when the brakes are used, ex(battery full, battery hot/cold, etc)
@@theamazoner4075 , thank you but I was just using the sounds like the anti-lock brake sound as an example of what it sorta sounded like. The anti-lock brakes was not activated. My question was, does the car have in place a system to use up the power that the regen system makes instead of over charging the HVB?
Hello from Ukraine, Professor Kelly! We are working here on a project to restore Ford Fusion 2017 plug-in hybrid. It has a broken transaxle oil pipeline including a transaxle nozzle so we have to replace a part of a transaxle case. We can't find any relevant information to confirm if Hybrid and Plug-in hybrid transaxle cases are the same. I would be grateful if you have the answer and you can share it! Thank you for your videos, it helps a lot!
I wonder how much Toyota IP is in these transmissions. Aisin is just about fully owned by Toyota. I still wonder why it took Toyota to the 4th gen Prius to get to the parallel axis design while Aisin has been producing them for much longer.
Good afternoon. Please tell me . Where can I get step-by-step instructions for removing the installation of the Ford Fusion HF-35 Hybrid Transaxle? Thanks Eugene
Professor, Can you explain why this Ford Fusion 2015 transmission has so many problems and have to be replaced? Our 2015 Ford Fusion with 112,000 miles broke down. I've seen lots of videos that show same problems with this model. Thank you for your great videos!
I'm dealing with it right now on my 2017 Fusion Hybrid. From what I've read so far, it is important to change the transmission fluid at or around 100K miles. Mine failed because of a leak from the driver-side axle output. I didn't notice the leak because of the felt/thin carpet cover (that goes underneath the engine compartment above the ground) absorbed most of the fluid.
Sir, I'm looking to take the L3 ASE test, and I'm wondering about how ASE classifies hybrid types in their certification test reference literature. "Type-1" seems to be a Toyota or Ford hybrid. "Type-2" seems to be an older Honda, and "type-3" seems to be a newer Honda style. Would you concur with that assessment, or am I confused?" This channel is wonderful, and I've learned so much from you, thanks.
Type 1 (Series-Parallel Hybrid System) is Toyota, older Ford, and FCA power split device based hybrids. Type 2 (Parallel Hybrid System) is older Honda integrated motor assist (IMA) systems, but there are many other hybrid brands that use the same system (Hyundai, Kia, newer Fords, VW, Audi, older GMs, Newer Hondas) Type 3 (Series Hybrid System) is Chevrolet Volt in transmission mode 4 and newer Hondas (E-Drive) I have video playlists on each type of hybrid system. Best wishes with your exam.
I believe on the 2019 model they switched to an electronic dial type gear selecter meaning the park pral is controlled electronicaly forgive my speling
I've heard of a few transmission failures on this gen fusion hybrids. I have one and want to do a fluid change, it seems hard to find any information about a eCVT fluid change.
Yes, some models had some bearing failures. Changing the fluid will not prevent the failure. If your transaxle is noisy, have a Ford dealer check it for you. They are fixing these under warranty. The fluid does not need to be changed until a very high mileage. Check the maintenance schedule in the owner's manual. I believe it is around 150k miles (241 km) Best wishes.
Охлаждение нужно не для того чтобы изоляция не расплавилась, а чтобы магниты не размагнитились. Магниты из редкоземельных металлов (неодим, празеодим) теряют свои свойства при нагревании.
Isn’t easy? And to think many C-Max cars are in the junkyard because Ford dealers told their owners that the fluid was “Lifetime”! When the HF-35 failed due to improper maintenance (at Fords direction!) the cars were not worth repairing! Ridiculous
At 18:34 in your video. I just want to let you know that the magnetic field in the motor "BOTH" attracts and repels as part of the process of moving the rotor. During rotation, if the stator magnet is "after" the rotor magnet, an attractive force is applied. But once the rotor magnet passes the stator magnet. The polority of the stator magnet is reversed and a repulsive force is then applied. Pushing that rotors magnet into the next stators magnet to be attracted to.
I just wanted to point out a mistake that you made a 17:20 in the video. You stated that you cannot swap the "V" wire? That's not true. You can take "ANY" 2 of the 3 wires and swap them to reverse the motor. This is not only true for AC mains 3 phase motors. But for inverter driven BLDC motors as well.
Besides a dealership, do you have any idea where I can find a re-manufactured transmission for my 2016 Ford Fusion Energi? I've looked high and low across the country and can't find one.
The magnet demonstration was the coolest thing I've seen in a while.
Thank you, it was fun!
Thank you sir, for this humorous enlightenment that the modern import vehicles have not seen the need to improve on the Ford Motor Company's Designs from way back in 2005 (having been with the Ford company since the 80's as a tech.)
You are absolutely absolutely wonderful and genius sir. I absolutely admire you work. I wish I would have someone with me to teach me all this stuff. I absolutely love working on these electric cars and really need someone's help to learn about them. And you are doing this without asking anything in return. You are given knowledge for sake of nothing that's is just amazing. Just brilliant. Can't thank enough for these videos.
Thank you very much!
Professor John Kelly I have driven Ford Fusion Hybrid cars for eight years now and really like them and their reliability. It is so interesting to see the inner workings of these cars. Thank you so much for the great explanations and demonstrations and detail and I understand everything you say. I just follow your lectures religiously. Thanks again.
This video actually helped me diagnose my vehicle. I drive a 2015 Ford C-Max energi, and him showing the auxilary transmission pump helped me identify the connector I needed to clean up. If you also get a P0C2- code, check that connector! It might be loose or dirty
I have a '17 Fusion Energi and had been wondering what it looks like inside and how it operates. Thanks for demystifying this system.
We purchased a Fusion Energi to go along with our Mitsubishi Outlander PHEV after the family learned the benefits of owing an EV - a full electric is a step too far given our poor public charging station network, but we only need to visit a gas station once per month now on average, sometimes longer. Both vehicles drive brilliantly, and ownership costs has dropped by $400 per month at the cost of $40 higher electric bills. Not a bad trade-off at all.
Thanks again for the in-depth explanation of the less known Ford Hybrid powertrains.
Thank you, it is a good vehicle
Great video as always Professor JD. I remember years ago the first time hearing the word "stator" was being used on an amusement park ride and was the latest and greatest technology alternating the power to magnets on a track to make a roller coaster go and stop. Too cool!!
Thank you, great example!
I can't have enough knowledge from your videos and explanations. Thank-you
Thank you very much
I dont deal with hybird specifically but as a tech this is full of knowledge that can be applied everywhere thank you for the vids !
Thank you!
I'm only 17, but I really enjoy working on cars and getting my hands dirty. But I have never had any proper training on working on cars, I have just been learning as I go. And your channel has really helped me a lot in learning all about cars and how they work, and WHY they do what they do! I love your work and please keep it up, it helps me so much. Especially that older video you did on the manual transmission and how it works. Thanks a ton!
Thank you very much!
Very interesting, I have worked on some Honda and Toyota hybrids, but the wife's Fusions seemed to stop working. I had thought maybe the trans had gone bad (seems like the stator is not capable of making the car move). I did a code scan - could not believe that there were no codes in ANY of the systems. Except when you shut the car off it tells you how many EV miles and Regen miles and those are almost always 0 or very .2 almost nothing. So I figured I better start doing some digging and learn some before I make a 5 thousand dollar mistake on what maybe a bad connection.
Thanks for the great video and all the info - will be watching more
Thank you
Thank you John for educating me on how my 13 Fusion works. I did notice something strange. Those 2 large (orange) high voltage cables have connectors the look identical. They don't appear to be keyed in a way to prevent them from being swapped. Maybe they are but it's not noticeable on the camera.
I'm a retired machinist from a large connector manufacturer, and that type of keying is extremely important.
Thank you. Good eye! They are actually mirrors of each other, so they will not interchange.
Списибо Вам за ваши труды! Лучший канал с обзорами трансмиссий!
I have not one but 2 2016 Ford C-Max Energi`s one brand new and one preowned with 12k miles. I love the cars and really enjoyed learning how the electrical operation works.
Thank you!
It's interesting to see a hybrid design convergence of the parallel motor generator for Ford, Toyota- GM, and Chrysler. This is the same for example with the internal combustion engine variable timing and direct injection and many more.
The various manufacturers experimented with their proprietary design until the industry decided toward common design concept.
Good point, thank you for your feedback.
Incredible! Thanks so much for this terrifically insightful video. I’m the new owner of a 2020 Fusion Ti Energi, and I’m amazed to see how accessible you make this info. Keep it up!
Sir my respect and appreciation for this outstanding lecture 👏 👏 👏. I knew zero=0 about how this cars mix the electrical with the mechanical part. You practically opened my eyes on this! Thank you very much!
Thank you for this outstanding video. We are now on our second lease of a Ford C-Max Energi after 3 happy years with a 2015 SEL. Glad to have these videos. Never really understood the true theory of operation until watching this. Subscribed.
Thank you
Thank you for the information. I want to put this system in a boat I’m building. I know I won’t get the regenerative power, but I’m okay with that issue. Will watch the rest of the videos to see why it wouldn’t work. Thanks, Chris
Thank you!
That's amazing that magnet strength that turns those rotors! Thanks for another great video.
Thank you!
Hi Professor John, on a personal point, I trust you and yours are well . Thank you for your gentle but engaging presentation, could watch you all day. I first found you on the Honda CVT which was absolutely brilliant. Thanks again. Seasons' tidings to you and yours. Pete on the Isle of Wight.
I'd like to hear more about the big micro-chips that are the brains of these motor controllers. It seems to me these chips are the breakthrough technology that made these game changing transaxles possible
Thanks for your feedback. I would also like to know the same thing.
Reading up about Brushless DC motors can reveal a lot of the background... I have limited hobby-level experience with one chip by Texas Instruments, the C2000 which is a microcontroller (embedded CPU w/ built-in memory) whose CPU core is optimized for the kind of math required. You quickly get "into the weeds" reading about this stuff but here's a few articles to chomp on - www.ti.com/lit/an/bpra055/bpra055.pdf ... www.ti.com/lit/an/sprt703/sprt703.pdf ... the C2000 series processor I evaluated once - www.ti.com/product/tms320F28027 - You quickly realize that the same set of processor "skills" required to perform motor control are also relevant with digital power conversion, think not 3-phase inverter for an EV but also 3-phase or single-phase inversion for producing AC power for the grid from DC (e.g. solar+battery) sources as well.
Outstanding educational fun. All the internet should be like this. (Keep the cats & kittens, obviously).
Obviously! Thank you!
Thank you for your great work! You’ve made most informative videos about hybrid transaxles here on RUclips. I haven’t yet seen anything close to this :)
Thank you very much!
Дякую Вам за вашу пізнавальну працю
Wye should be how its connected, all three hot wires are connected to one neutral, at least for a three phase AC stator. The other is a Delta which has 4 wires, three hot and one ground. Company I worked for used wye connection on our three phase 400 hz systems, but again these were AC inductance motors. So Im not sure with this setup. Our Stators looked exactly like those too, I use to make some of the coil windings myself, also the stator stacks, then they were sent out to be inserted. Women were better than men for inserting the coils. When the completed stators returned to us they were then impregnated with a 2 part epoxy in a vacuum chamber so there was no air in the stator windings. The wires are called magnet wire, the coating is extremely tough, that tranny couldn't get hot enough to melt that coating under normal operation. The wire itself is fully annealed.
Enjoyed what I did and I thank you for an awesome video...
Great clear concise explanation of the E function glad I found this channel. You sir remind me of my better engineering proffesors.
Pretty cool to see the stators I build in action
Great video, thank you. I've got a 2014 fusion hybrid and you have a wonderfully straightforward way of breaking down and explaining all the components. One small criticism ... I don't know exactly how the fusion inverter drives their stators but if it is like a typical VFD system I suspect your voltage explanation is a little off. Typically a 3 phase system like these motors are not really 2 on, one off so much as a staged change where one is voltage is always 1/3'd of the way ahead of it's brother, they lead each other around more than alternate.
Thanks for breaking this down. I've had two Fusion Energi models (13' & 19') and have found the design to be terribly durable so far. Since there is no torque converter, would it be just a fluid change and not a flush?
Correct. Thanks for watching
The power split system on my 2014 CMAX doesn't appear to be operating in tandem anymore. It used to be that over certain load levels both electric and gasoline motors would be working together then the electric motor would take over when the load was light. We just got hit by 34days worth of -40 degree celcius weather and upon the 3rd day I discovered the hybrid battery had dropped to near zero from full charge the night before. Since then when driving it's either full electric mode or gas only mode regardless of battery charge level and the two only work in tandem for very very brief periods maybe a few seconds at a time. I can hear the switching from inside the car. I don't know enough about the system to judge if prior operation was normal or if the current operation is normal and the cold weather had nothing to do with it. It's still under warranty 44000km. Fuel economy sucks too 33mpg (city) and that's with the ever optimistic digital readout, it's actually closer to 30mpg. Anyway, any ideas?
Most engine coolant temperature sensors register -40 degrees C when there is an electrical open circuit. The system may have been tricked into thinking there is a malfunction. The very cold weather will certainly affect the operation. I would have a Ford dealership check it for recalls, technical service bulletins, and any malfunctions that have not illuminated a check engine light. Best wishes.
@@WeberAuto I've an appointment set for this Monday we'll see, I actually really like this car and hope they get it all sorted. While the fuel economy is a bit disappointing for a hybrid i'm coming from a 7mpg truck so happy any which way. Thank you!
Thanks for all your hard work in producing these video's. This old boy is learning a whole lot. Looking forward to the detailed electrical system video (I live for that kind of stuff !!!)
Thank you, it is a lot of hard work, but it is also how I have "fun". Have a great day.
Interesting how similar the Ford and Toyota designs are. I’ve heard the original Escape hybrid has one of the most bulletproof drivetrains ever made, and taxi services have consistently been able to pull half a million miles+ without trouble. It seems that the Achilles heel of the Toyota system has historically been the motor winding(s) burning out. Now that they’ve switched to the bar-wound stator assembly (like GM has been using for years), I have a feeling the P610 won’t have these issues. It looks like this will be a very good transaxle, so long as the heat exchanger is effective enough to cool the transmission fluid and prevent the ATF from cooking.
I agree, thanks for your feedback!
I've read several times that Toyota and Ford share R&D on hybrid platforms so makes sense they would have similar systems.
Ford did use the same transaxle manufacturer (Aisin) for the Escape Hybrid that Toyota uses, but Ford did its own research and discovered similar patents, so Ford and Toyota exchanged patent rights. Ford never copied Toyota ideas.
Thanks for your work, just fyi we’re about to trade in our 2017 C-Max energi with 340K miles for a lower mileage 2017 C-Max. Had to be a rideshare driver in 2017 after years as a taxi crown Vic driver. Kudos to Ford for the excellent vehicle and wish they had a 2022. The best vehicle ever and has never needed a brake job!!
Wondering did you ever change the trans fluid? My fusion hybrid just 200k and just realized it was suppose to be replaced at 150k
@@beammeupscottsp7952 yes, trans fluid change was done twice and most recently was at 310k .. sad to say a large deer ended that vehicle just one week after we installed a new ford factory rebuilt engine. we’re now using Tesla model 3 with no issues after 33K miles and 5 months in service . TY
@@jamesmonroe8962 oh wow! I’ll make sure to change the trans fluid as soon as possible then, hate to hear about the accident but congrats the on the model 3, will go full ev but not until the fusion hybrid decides to give out. If there’s any other maintenance service you did please let me know!
Love this video and the way you explain every aspect, thanks for sharing your knowledge
Wish people that makes videos like that take notes from you.
Thank you!
Thank you sir! Nothing in our Ford service information on the electrical side. I want to rip into one myself but the cores are expensive.
Thank you. You are correct, nothing in service information except a schematic
Thank you for these videos, they are helping with my disgnosis of the common P0A7C on the 2010-2012 Fusion Hybrids. As of yet, I don't know of any solution, and Ford's TSBs seem ineffective.
Pretty sure I've narrowed it down to the coil temperatures, which means I need to drain and fill the transaxle fluid (and measure how much is in mine).
incredible job, top notch presentation, my auxillary pump went bad, i have to replace it...
Outstanding video Professor John. I have just bought a 2014 Lincoln MKZ 2.0L FWD Hybrid with The Hf-35 xCVT trans and it is leaking out about 3qt, but the car drives great. Because of the leak the Transfer-shaft assembly (EG9Z-7H348-A) bearing and cup should be shot, but those parts only cost US $410 right now. Is it possible to put a rebuilt used HF35 eCVT or even a newer Ford 2017-up HF45 eCVT and not have to reprogram the power transfer unit? The only cable that comes out of both trans are the hi-voltage drive/regen motors and the low-voltage data cables (that reads both motors temp and speeds). From what I have read; the HF35 has no brain or need for VIN programming itself. I ask because my locale Lincoln Dealer just quoted me US $10,000+ to replace the HF35, recalibrate the Lane-departure system, and realign the wheels. Since I was not born yesterday and value my family's treasure, I figured I would ask an expert. The car is beautiful and still drives it just need seals and bearings but no trans shop in or near Chicago will touch these eCVTs due to Ford's EV service equipment requirments (an anti-static bay). I have removed FWD trans and replace clutches before and I am thinking of removing and rebuilding my own trans because of inflated dealer costs. Any help you can provide would be much appreciated "for eductional info only... lol". Thank you for your time, sir.
BTW: Can you do a trans removal video on the HF35 and HF45? That would be amazing.
a true professional, thank you ...
Thank you!
you sir are an extremely impressive man.. TY for all your knowledge and work!
I appreciate that!
Excellent video, demo and explanation of the HF35 unit. I'm going to watch the other ones now. I'm buying a FFH very soon😁👍👍
I have been following the Lincoln vehicles from the mark series up to the 2016 model MKZ hybrid. Since the Ford fusion hybrid is built at the same plant in Hermosillo Mexico as the MKZ hybrid I believe they are both Same .
I enjoy all your videos about this particular product I do on wiring diagrams two vehicles from 2014 through 2019 on the MKZ or a fusion they’re both the same book and the energy thank you very much you do a Netflix job regards
I know I'm late to the party on this one, but have you considered discussing how the HF35 needed to be redesigned in 2015 due to a known design flaw which caused very rapid bearing wear and potential failure/need to replace the transmission on many Fusion/C-Max hybrid cars. I would be interested to learn what they changed with the should-have-been-recalled-but-didn't design.
2015 Fusion Energi does not have a B position on the trans. control lever, it has a L position instead .
Thank you, I had that wrong.
Your lecture and explanation was great thank you
thanks for the excellent explanation, wondering if you can add the expected failure could happen to components ?
Is mercon LV petroleum driven? I used Molly to reduce the bearing friction and it did. Wonder about its effect on the windings coating. Also this time I wanna use DCT full synthetic Lv, fluid which is very close to mercon. Only thing I wonder about is the coatings on the windings.
Thank you so much for bringing all this explanation 👏🏽👏🏽👏🏽👏🏽.
Smart man with a very complex system...wow hate to own one when things go bad and the warranty is over. No DYI backyard repairs with this.
God bless you. Thank you.
Thank you very much
Thank you very much for sharing your valuable information, blessings and thanks again.
thanks sir for sharing this information... how much the output voltage for the generator? and what is the input voltage of the motor?.. why they called it high voltage? is more than 2000 volts? how the brakes gives the high voltage?
Very informative. Is this the same 2.0 hybrid that is in A Lincoln MKZ?
Fantastic Video on so many levels I have cmax engi wow what vehicle
Thank you!
Would you have this month's contents for the 2012 model box? What is the specific model of this year's box?
Thank you Professor, Fantastic video!
Thank you!
Just bought a 2018 Fusion energi. I'm impressed. Everywhere I read it says it has a CVT. Looking at the gear train in this transmission I do not see a means of varying the ratio. Am I missing something?
The rotational speed difference between the engine and the motor “A” creates a variable gear ratio. Thanks for watching
@@WeberAuto Sorry.. that is not the meaning of a variable. This set up is still a constant ratio.
It actually provides a variable gear ratio with underdrive ratios, direct drive, and overdrive ratios. It works just like the Toyota transaxles. See my video here for a better description ruclips.net/video/O61WihMRdjM/видео.html
Professor, could you please post an image of the fluid level port for the HF-35 that you mention at the 14:00 minute mark of this presentation; I just changed the Mercon LV on my 2013 CMax and want a better idea of a correct refill than just the replacement of fluid volume removed. Thank you for sharing this information.
Pause the video at ruclips.net/video/MZf_BUuW5Qg/видео.html The Fluid Level Check Plug has a yellow label and is shown in the bottom right of the screen. Thank you
Fantastic! Thank you for pointing that out, I had missed it on the first viewing; will share with another person who has a DIY fluid change video posted.
Thank you for creating these videos!
Hi. Can you please tell me, my friend and I cannot understand how the planetary unit works? Is there a ratchet or some kind of overrunning clutch? Or why, when the engine is off, the planetary gear itself with the traction motor rotates, but the engine does not? Through what mechanism is the torque transmitted from the engine to the main gear?
If so, does it have a ratchet that has free play in one direction and does not have it in the other?
Thanks for the video, very informative
I use a wheelchair and just bought a 2010 E450 hybrid . Having problems finding manuals or mechanical manuals for the Azure hybrid plus that battery. Any suggestions? I want to use this e450 cutaway limo wheelchair lift bus. I'm disabled Deaf Veteran: I'm so grateful for CAPTIONS! Thanks
18:33 actually half of the magnets are being pushed and the other half pulled. when it comes to magnets it's very confusing if you just look at their poles. if you look at the magnetic field lines actually it isn't pull or push but simply a rotational force
Thanks for your feedback. I was describing the operation on a very basic level and showing the relationship to the resolver cam positioning. Yes, it is more complex than what I was describing. Have a great day.
Fascinating, as always! Thank you.
Thank you!
Any update on fusion transmission bearing in the 2017 because the last model have reacal on transmission bearing
They fixed the issue
how much power (KW) has the MG1?
I own a Ford fusion hybrid and I have to admit I laughed when I saw the new Prius transaxle
I own a 2016 fusion Se hybrid too, but Toyota’s gears are like 20 times better, there are many fusion gears that are failing... way too many
The Ford and Toyota hybrid transaxles are made by Aisin , a Japanese company which got its start during World War II. it has been wrongly reported that Ford merely license Toyota's design. In fact Toyota and Ford just agreed not to sue each other for patent infringement on hybrid transaxles so they do use the same basic design. The planetary gear set itself dates way back to at least the design of the Ford Model T.
@@aggressor9517 Source?
Source for what?
@@aggressor9517 of all the failures... News... Articles.... Reports.... The 35 transaxle tech is toyota and ford based. Shared tech. The transaxle is actually quite robust and taxi fleets are getting 400k-600k miles on original gears and batteries.
Wow. Great and very informative video. Thank you!
Thank you
Thank you guys lots of info and price is right. Goldmine for techs that want to learn
Thank you
Again professor, another great video. Thanks a lot.
Any tips on getting one of these rebuilt or replaced with a rebuild?
i have 2018 ford fusion hybrid my transmission makes winning nose ones in a wile is there a fluid treatment for it thanks
Can You increase power of hybrid drive? Like chiptuning
Could you please answer a question for me, I have a 2019 Ford Fusion Hybrid, as I was going down a long hill the other day and the car started making a strange noise, sort of like the sound anti-lock brakes makes only not as bad. I noticed that the HVB was showing that it was maxed out with power, what happens when the HVB is maxed out but the dash symbol is showing that Regen braking is still charging, how does the system use up the over charge that's coming to the battery, is there some system to burn off that extra energy? As soon as I used some of the battery power it never made the noise again.
That’s likely the electronic brake booster if it sounds like the abs system when running in ev mode there isn’t an engine running to produce a vacuum for the brakes to instead they use an electronic pump that will run occasionally to give you boost when the brakes are used, ex(battery full, battery hot/cold, etc)
@@theamazoner4075 , thank you but I was just using the sounds like the anti-lock brake sound as an example of what it sorta sounded like. The anti-lock brakes was not activated. My question was, does the car have in place a system to use up the power that the regen system makes instead of over charging the HVB?
Is it common for 2014 fusion energi trans case crack at one of the bolt location and start leaking trans fluid after 8-9 years?
Hello from Ukraine, Professor Kelly!
We are working here on a project to restore Ford Fusion 2017 plug-in hybrid. It has a broken transaxle oil pipeline including a transaxle nozzle so we have to replace a part of a transaxle case. We can't find any relevant information to confirm if Hybrid and Plug-in hybrid transaxle cases are the same. I would be grateful if you have the answer and you can share it!
Thank you for your videos, it helps a lot!
I believe they are the same case
I wonder how much Toyota IP is in these transmissions. Aisin is just about fully owned by Toyota. I still wonder why it took Toyota to the 4th gen Prius to get to the parallel axis design while Aisin has been producing them for much longer.
Good afternoon. Please tell me . Where can I get step-by-step instructions for removing the installation of the Ford Fusion HF-35 Hybrid Transaxle? Thanks Eugene
Professor, Can you explain why this Ford Fusion 2015 transmission has so many problems and have to be replaced? Our 2015 Ford Fusion with 112,000 miles broke down. I've seen lots of videos that show same problems with this model. Thank you for your great videos!
I'm dealing with it right now on my 2017 Fusion Hybrid. From what I've read so far, it is important to change the transmission fluid at or around 100K miles. Mine failed because of a leak from the driver-side axle output. I didn't notice the leak because of the felt/thin carpet cover (that goes underneath the engine compartment above the ground) absorbed most of the fluid.
Sir, I'm looking to take the L3 ASE test, and I'm wondering about how ASE classifies hybrid types in their certification test reference literature. "Type-1" seems to be a Toyota or Ford hybrid. "Type-2" seems to be an older Honda, and "type-3" seems to be a newer Honda style. Would you concur with that assessment, or am I confused?" This channel is wonderful, and I've learned so much from you, thanks.
Type 1 (Series-Parallel Hybrid System) is Toyota, older Ford, and FCA power split device based hybrids.
Type 2 (Parallel Hybrid System) is older Honda integrated motor assist (IMA) systems, but there are many other hybrid brands that use the same system (Hyundai, Kia, newer Fords, VW, Audi, older GMs, Newer Hondas)
Type 3 (Series Hybrid System) is Chevrolet Volt in transmission mode 4 and newer Hondas (E-Drive)
I have video playlists on each type of hybrid system. Best wishes with your exam.
@@WeberAuto Thanks for taking the time to respond. Your students are truly blessed to have you as a professor.
That`s what they call a brush less motor . Much better!!!
Thank you!
I believe on the 2019 model they switched to an electronic dial type gear selecter meaning the park pral is controlled electronicaly forgive my speling
I've heard of a few transmission failures on this gen fusion hybrids. I have one and want to do a fluid change, it seems hard to find any information about a eCVT fluid change.
Yes, some models had some bearing failures. Changing the fluid will not prevent the failure. If your transaxle is noisy, have a Ford dealer check it for you. They are fixing these under warranty. The fluid does not need to be changed until a very high mileage. Check the maintenance schedule in the owner's manual. I believe it is around 150k miles (241 km) Best wishes.
Amazing explanation thank you!
What is your advice for a fluid change for transmission
Охлаждение нужно не для того чтобы изоляция не расплавилась, а чтобы магниты не размагнитились. Магниты из редкоземельных металлов (неодим, празеодим) теряют свои свойства при нагревании.
@weber Can I replace my 2013 transaxle with a 2015??
Interestring, it makes me want to change the oil in the "trans" of my C-max. Thanks.
Isn’t easy? And to think many C-Max cars are in the junkyard because Ford dealers told their owners that the fluid was “Lifetime”! When the HF-35 failed due to improper maintenance (at Fords direction!) the cars were not worth repairing! Ridiculous
At 18:34 in your video. I just want to let you know that the magnetic field in the motor "BOTH" attracts and repels as part of the process of moving the rotor. During rotation, if the stator magnet is "after" the rotor magnet, an attractive force is applied. But once the rotor magnet passes the stator magnet. The polority of the stator magnet is reversed and a repulsive force is then applied. Pushing that rotors magnet into the next stators magnet to be attracted to.
Thank you, you are correct!
I have found two cmax energi 2013 transmissions with bad bearings between 120k and 150k it seems this is a common problem
I just wanted to point out a mistake that you made a 17:20 in the video. You stated that you cannot swap the "V" wire? That's not true. You can take "ANY" 2 of the 3 wires and swap them to reverse the motor. This is not only true for AC mains 3 phase motors. But for inverter driven BLDC motors as well.
True, I was referring to 3-phase wiring configuration on these systems only. Thanks again
Thanks for another great video
Thank you!
are that magnets of neodymium type?
Great videos! Do you know how the 2017+ hf-45 differs from the 2013-2016 hf-35 unit?
It turns out that the HF-45 was never released. I understand it will be used in an upcoming hybrid SUV
@@WeberAuto So maybe it is in the new Ford Maverick?
@@DanNPTRI I suspect that is true. Probably the same powertrain as the Escape hybrid.
@@DanNPTRI it is a Kuga
Another great video. Liked in advance!! Thanks.
Thank you!
Thank you, Professor.
Thank you!
do you know where can i find parts for 2015 ford c-max hybrid transaxle?
Besides a dealership, do you have any idea where I can find a re-manufactured transmission for my 2016 Ford Fusion Energi? I've looked high and low across the country and can't find one.
I do not know, best wishes
@@WeberAuto I searched high and low and it's either Ford or a salvage yard. :(