2013-2021 Ford Fusion Hybrid Li-Ion Battery
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- Опубликовано: 2 июн 2024
- 2013-2021 Ford Fusion Hybrid Li-Ion Battery Service
0:00 Introduction
0:54 Battery kWh rating
Main battery components
1:32 Service Plug Grip
1:44 DC-DC Converter
1:52 Battery Energy Control Module (BECM)
1:59 Battery Junction Block
2:12 Battery Cells
2:26 Air-cooled battery airflow
2:30 Battery fan
2:50 Battery vent
3:00 Inlet air temperature sensor
3:06 Internal cell temperature sensors
4:00 High voltage (HV) disconnect procedure
4:45 Service plug grip removal warning
6:30 HV Interlock circuit
9:20 Removal of battery covers
10:00 Battery safety warning label
10:55 BECM electrical connections
13:40 BECM Warning label
14:02 **(see note below) Personal Protective Equipment needed
14:40 Service grip connector bracket removal
15:20 Cooling fan removal
15:36 Side and front cover removal
15:48 Rear cover removal
16:00 DC-DC converter electrical connections and operation
17:05 DC-DC converter cooling
18:40 HV Voltmeter checking
21:45 DC-DC converter output
23:22 Hybrid battery junction block harnesses and removal
27:20 Hybrid battery junction block connections and components
29:17 DC-DC converter fuse
30:30 Positive battery harness and connections
31:28 Positive battery harness and connections
32:00 Auxiliary harness connections
34:00 Li-Ion battery cover removal
35:20 Under the cover inspection
37:42 Tamper-resistant nuts
39:07 Cell stack voltages
29:50 Individual cell voltages
40:00 Cell pair voltage addition
41:31 Total cell stack and battery pack voltages
41:59 Battery vent system
The Li-Ion battery from a Ford Fusion Hybrid has 76 3.7V cells (281.2V) nominal and a ~5 Ah rating = 281.2 x 5 = 1406 Watt-hours or 1.406 kWh
**I failed to comply with three OSHA standards in this video:
- 1910.137(c)(2)(vii) - Protector gloves shall be worn over insulating gloves in this video.
- 1910.137(c)(2)(vii)(D) - Insulating gloves that have been used without protector gloves may not be reused until they have been tested under the provisions of paragraphs (c)(2)(viii) and (c)(2)(ix) of this section.
- 1910.137(c)(2)(vii)(A) - Protector gloves need not be used with Class 0 gloves, under limited-use conditions, when small equipment and parts manipulation necessitate unusually high finger dexterity.
I apologize for the error on my part. I was not aware of the requirement at that time. I now offer full updated training on PPE usage and following the proper OSHA regulations. See www.weber.edu/evtraining for more information.
Weber State University (WSU) - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab.
This episode covers High Voltage Hybrid Electrical Systems - Specifically the 2nd generation (2013-2016) Ford Fusion Hybrid 281.2 Volt Li-Ion battery system. Learn what is serviceable and how it works.
This topic is taught as part of our 4-year bachelor's degree program. For more information on the Weber Automotive program, visit: www.weber.edu/automotive
This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see www.weber.edu/automotive/J_Kel...
Thank you, John. I am a tech writer. Decades ago worked as a junior mechanic for a Fiat-Triumph dealership. I've maintained my own and family cars over the years, though less since I started buying hybrids in 2006. My 2014 Ford Fusion Hybrid Titanium ODO is now at 136,000 miles. I was contemplating what I would do when the battery pack died. After watching your video, I feel I could do the job, yet doing it with the battery in the vehicle would be a lot more effort than it was for you on the bench - and you worked pretty hard to get it apart. So I may pay a qualified shop to do the work when the time comes. The added explanation of how the 12V battery interacts was very helpful. You did a great job of explaining the whole system, and I love the "why" and the circuit descriptions.
I'm not sure how much the battery module weighs but I'm pretty sure 2 people could remove it through the back seat without too much effort. Still, I hope that day doesn't come with my 2015 SE. Fortunately, my current job involves a company van so I haven't put many miles on my car in the last 4.5 years. Blue was my daily driver for 4.5 years and the first 60k miles. Now it sits in the driveway and looks as pretty as the day I bought it with only 65k miles on it. :)
Thanks for all the good information. I had to replace the junction box that you showed us at 27 minutes on my 2015 fusion with 135,000 miles on it. I was able to see on the shop scanner that the contact points were opening after the car had started and been running for about 4 or 5 minutes. Once I was able to find the part (parts people seem to be clueless) and installed it; gas mileage returned to 50mpg. Once again awesome and well organized information TY
Glad it helped. Thanks for watching
After owning my 2014 Ford C-Max Hybrid (same system as the Fusion) for 6 years now it is really great to finally get a good look at what makes the Ford hybrid system work. Just finished this video and yesterday watched the one on the trans-axle. The car has been dependable as all hell, after decades of Ford being considered a bit of a joke when it comes to reliability. Really appreciate the level of detail and especially the helpful bright yellow labels on every component. With this information it is so easy to get a quick grasp of what you're looking at in frame before even watching through the video.
I have been wanting a ford fusion hybrid and hopefully that will become a reality next week.. only time will tell... I was apprehensive based on the stories of how expensive the batteries were among other expenses hybrids have...
BUT....
You my dear sir are a saint, this video is amazing! You have taken out all my fears of understanding how this battery works and its funcionality. I would subscribe to your hybrid school "online" classes if I found them...
Your systematic approach, clarity, labeling and attention to detail make understanding all these web of wires an easy task for sure. I did not even know that the hybrid doesn't have an alternator and that the DC-DC CONVERTOR was considered that in this case.. so awesome to have found your channel..
I will be watching ALL your videos in the coming weeks as I have hip replacement next week.. healing time is perfect time to watch and learn for sure!!!!!
THANK YOU... THANK YOU so much for being online and teaching us how to understand these new concepts. I have only positive words for sure.
One thing I would like to know though.. are the "sensing" connectors interchangeable? You don't mention if they can be reversed or if it matters.
I love your comment when you say that you like to take things apart as far as you possibly can ! To me that is the definition of a true engineer and innovator. Thanks for sharing your great depth of knowledge. I look forward to your films every time.
Thank you!
I own a Fusion energi out in tooele, and these videos are super helpful to me, thank you so much for posting them!!
Thank you very much, it is a great car. Feel free to stop by and visit sometime
Professor Kelly, I wasn’t sure where to ask this question but I have a 2015 Ford Fusion Energi Titanium and this morning just replaced the 12V Accessory Battery. I know of no way to electronically test a Lead Acid Battery except by visually looking into each Cell. We had purchased this car in September of 2015 so I believe the Battery was about a year old when installed making the Battery about 5-6 years old. But last year I have noticed that the Hybrid Voltage Level deprecated from 21 Miles to 13 Miles. Every Ford Dealership said that I would have to leave the car overnight to perform a diagnostic test and the fee was outrageous so I decided to live with it. I had purchased a replacement battery from Ford this morning and noticed that the voltage on the Hybrid Battery Level Indicator went from 13 Miles to 16 Miles. The old Battery read 13.8 Volts but the acid in the cells were low and the fins had a lot of corrosion on each of the fins. The new battery read 12.68 Volts before installation. I didn’t use any type of memory saver like what other people used to keep the accessories up to date. Before going to work tonight I checked the voltage level on the hybrid indicator and it read 17 miles. I only had the chance to drive about five miles and installed the 110V charger. The only reason why I replaced the battery was that my daughter had driven the car and said that the cars clock had gained one hour. My wife also had told me afterwards that she thought that I was messing with the car and that she didn’t inform me of the anomalies with the cars electrical system. I look at your videos to learn about this car and I watch your videos which I truly like and since you like to “Open Things Up,” I don’t have to. Thank you for that. Sorry about this long question but I do understand that automotive batteries last about 3-5 years and most people do not notice any issue until it’s too late. Especially with this car one would not get the indication until they are away from home and I could imagine the bill they have to pay for a simple fix. If I could have explained this any simpler I would but I hope that you can make a video of a battery in its weekend state and what anomalies would occur months before the total failure of the 12V battery. Also I drive a 2004 Explorer 99.999% of the time.
This comment is a bit late... but, I noticed you took a little shock at 38:06 when you had a hand on end with elbow on the table and touched the other stack with your other hand. Good thing you had the gloves for the extra resistance! Such a great example of why those gloves are needed. This is a great video, very descriptive and helpful.
great videos, just found your channel and this is what we need on youtube, intelligent people to teach great things!
Thank you very much
You can explain anything and do it like no other. Thank you
Thank you!
Congratulations Prof Kelly, hier in Brazil we've started training the Bosch Service Workshops. I´ve never seen the comments like these with so many details on it.
I'll use this in our trainings.
I hope to see hier other helpful videos.
Thank you very much! Best wishes
Thank you for these great videos! I just bought a 2022 escape PHEV as my first EV.
There is a lot going on inside of that battery container Professor!! Enjoyed the review.
Thank you!
Thanks this was full of information that i wanted to know about that hybrid battery.
Sir thanks for the awesome class again, I learn a lot
These cells are insane! Best on the market
just like everything about this guy. thank you
Thank you!
He is great
This is wonderful and incredibly informative. I would really love to see a companion video for the larger plug-in hybrid battery for the fusion energi model.
Well done professor. Fantastic vídeo. Congratulation.
thank you for sharing your great depth of knowledge .
You are one smart individual. Thanks for making this video. I bought an MKZ 2015 hybrid to help offset my driving cost. I’m a unpaused volunteer and was driving 4000 Kim a month. My car is amazing it is getting 5 LTS per hundred kilometres . I would love to put its type of drivetrain in a 2011 or older ranger. Do you know of anyone who has done a conversation like that?
Excellent teaching video !!! Kind regards from Uruguay !!!
Yes, at 37:42, they are a 12 point nut holding down the bus bar, I think it's 8mm, also under the black caps there are jumpers to isolate the cells.
Thanks for your demonstration. You are the best.
Thank you
Thank you so much, Dr. John.
I hope you can give us some episodes of wiring diagrams.
Thanks so much 😊
I'm using 30 of the Ford energy battery sections as a power wall for my off grid solar system
A 5/16 deep socket can remove the custom nuts
press down hard when breaking the nuts loose
Use metric flange nuts to replace the custom nuts
I used prius hybrid battery nuts and they fit fine
Great videos thanks
Good to know, thank you
12 pt socket I’m assuming?
Thanks for this information about hybrid battery.
You are welcome
My 2013 C-Max PHEV has been having hot battery problems so I was checking the blowers. They appear to be the same as the one in the video. The blowers on my car have brushless motors that run on 12VDC. The connectors have four wires. Black is ground, pink is 12VDC, blue is on-off control, and yellow is a tachometer signal. The black and pink wires are about twice as large as the blue and yellow wires. The blue wire is normally at 12VDC with the blower off. Grounding the blue wire or otherwise reducing the voltage below about 5 volts turns the blower motor on at full speed. I'm fairly sure the controller in the car pulses the signal on the blue wire to control the blower speed. Blowers like the ones in the C-Max can be tested by applying 12VDC with positive on the pink wire and negative on the black wire. Connecting the blue wire to the black wire will put the blower into operation. The yellow wire should not be connected for the blower test.
Professor Kelly, my hybrid battery is now holding a 9 mile charge. I’m surprised no one has talked about the capacity depreciation on the older Ford Hybrid Batteries. I brought my car to the dealership and they showed me the owners manual’s one sentence that the Hybrid battery deprecates over time. That one statement voids the warranty. It would be nice to get a larger capacity battery made for the older cars.
I got 100k miles on my 2019 model, and the battery now is just good enough to get the car rolling and accelerate. It used to do about 1 to 3 minutes on a charge of slow speed driving, but now cut down to 1 min driving. The batteries have a 100k mile warranty, but the warranty isn't honored by ford unless the battery won't work anymore.
A replacement is $7k, and a second hand with God knows how many miles on, is $1.5k plus ship, handle, and installation fees.
Horrible investment! Nearly all batteries die before 170k miles.
That’s complete bs take it to another dealer
Yeah they had no capacity warranty on the batteries, so as long as the car still starts there is nothing that Ford will do warranty wise. Never buy an electric vehicle without a battery capacity warranty.
I'm by Chicago, and there are hybrid shops that make entirely new batteries and install them for you for about $3.5k the last I looked. They do refurbish factory packs as well, those are about $1k less. I have 80K miles on my hybrid, and I'm the only owner, but I have noticed maybe ~1MPG less than I used to get. Performance has pretty much stayed the same going on year 8.
Really informative. I love it. Subscribing for sure. Great video and information here. Thank you.
Had two packs of them, never got to a point to convince myself to utilize them! Be Well
Thank you
Thank you for making an informative video! only thing I could suggest is next time add loud rock ‘n’ roll music and make the video about 22 seconds long. But seriously.... nice video. Thank you.
Thank you sir...gives me insight to what may be in the new Maverick Hybrid but liquid cooled.
always interesting, thank you ...
Thank you!
Ford has stopped production of Mondeo hybrid in 2017 in China, but I can still find several “new” cars in stock. However, I am wondering if the two years storage would harm the battery. Are these cars worth buying? Need your advice.
الله عليك يا حبيب والديك thank you very very much
Thank you!
is the dc/dc converter fused or otherwise current limited on the output, or only on the input? how much current can it supply to the lead acid battery, and what happens if this value is exeeded?
Hi John, I have a question to you. Is it possible to replace battery pack on 2018 ford fusion energy battery pack with 2017 or newer ford focus electric battery pack? I was thinking to increase significantly rage of the car. I appreciate if you explain why yes or not. Anyway it is very useful this video, that explain in details how it works.
I have Ford fusion 2013 and the millege went down suddenly , and no errors appeared so any thoughts .
Best regards yr vedios were helpful
Watching the other WeberAuto videos, Prius Prime and Nissan Leaf all have a battery heater system to prevent cold damage. Does the Fusion Energi have it has well? If not then charging in cold weather (below 0C) woudn't be good for battery longevity.
thought the ford 2017 was water cooled ... looking at a wrecked c-max learning everything I can since i cant find a volt. thank you very much.
I am not entirely sure if anyone asked, but is it possible to add a 2nd ford fusion energi battery in the same trunk and make them work together, to extend the capacity?
Professor Kelly,
I have a 2014 Ford Fusion hybrid.. my question for you is what would cause a loud humming noise from the front end and when it stops humming it pulls the whole car like it’s getting too much power. I just got my oil changed, and the mechanic said that it sounds like it is the Hybrid battery. Like it’s coming from the metal box in the engine. Any ideas would be greatly appreciated :) thank you! I wish I could send you the video of my vehicle..and the sounds.. when it’s out of EV mode it makes the noise.. I don’t know if that helps.. I’ve only had this vehicle for a year and it has 65,000 miles on it
Very good review. And please tell me as a proffesional which baterry is better Chevrolet Volt or Ford Fusion Plugin hybryd and which car is better?
Is there any type of air filter for the hybrid battery cooling fan?
If so where is it located on a 2017 Ford Fusion Energi?
I recently had a STOP SAFELY NOW warning and shortly after I also had a battery warning light on.
Love your video's. So how is the combustion engine separated from the electrical part of the engine
fantastic video
Thank you
Great information and explained with understandable care. Thank you.
What do you think of adding a seperate high voltage battery to a 2013 Lincoln mkz to increase mileage on pure electric? Parallel?
That HVTB temperature sensor is essentially the same as a standard 19C734 evaporator temperature sensor. To answer your question, yes it can be serviced separately.
Thank you, that is good to know
Very good video!
Thank you!
Hi Professor I own a Ford Fusion 2015 circuit breaker 400000 km Do you need to change the battery I feel weak in the capacity of the vehicle Thank you very much
Thank you for providing these videos!
Thanks a lot for your explanation. And I have a 2018 ford fusion hybrid am asking if I can run the car without the hybrid battery when I remove the fuse , drive only with the gasoline engine
Typically not. The 12V system in Hybrids is generally dependent upon the IMA system for charging, meaning the transmission/engine (regen braking or engine charging) will end up charging the 12V (after passing through IMA), instead of an alternator (the electric motor essentially replaces the alternator). Not to mention the ECU is going to also play a factor into whether the car operates or not with the battery disabled.
I have had the displeasure of driving both a 03 and 07 Civic Hybrid with a bad IMA that (for whatever reason) decided to also stop 12V output. Which means anything electrical outside the electric motor (EPS, vehicle lighting, instrument cluster, various sensors) stopped working. Not an experience I'd recommend. Once was driving down I-5 through Seattle at night and everything shut down. Another time was driving in downtown Seattle. No power brakes, steering, nothing, coming down a hill. Yikes.
Did the battery arrangement change for the 2020 HVB? Running the BECM POS_BAT_PACK_V monitor, the engine started at 136V and shut back off at 140v. Seems that would be a 2P38S arrangement of the cells.
Hello Prof. Kelly. Just want to ask if you know that the Fusion Energi (the plug in hybrid variant) shares a similar battery pack design or uses similar cells as this regular Fusion Hybrid.
It is very similar, but much larger 7.2kWh (I think)
I own a 2016 Ford C Max Hybrid SEL. I have a question, can the 7.2kw ford battery be installed in place of the 1.4kw battery?
Hello ,I have a question about it hybrid batteries. If I replace it the battery I have to reprogram the battery with the dealership?
i was able to use a 1/4 drive 5/16 6 point deep craftsman socket for the nuts.
Very interesting video. I have a 19 I just bought used. I had it for a month and a half. Now the 12 V battery will die if it sits for more than 24 hours and need to be jump started. Would the system detect and report no/low voltage from the dc/dc converter? Or what could be putting a draw on that battery?
I owned A 2015 Lincoln MKZ hybrid where the battery would be dead after approximately 20 days no one can fix it. The vehicle was deemed to a lemon and I received some money for it from Ford. I’m now on a 2016 and it seems to be working very well well over 35 days.
I suspect that some of the relays are either stuck or they just don’t disconnect from the circuits on the battery. This can easily be checked but it will take some time to determine which circuits are alive after shut off. Good luck
Thank you sir. I have a 2011 MKZ with the NIMH battery with only 47,000 miles. My question is do the batteries wear out from purely the number of charge/discharge cycles, or is it also a function of age or both and why? Mine runs good but I wrestle with this question. Thanks.
Both. Battery degradation occurs primarily due to 1 factor, chemical breakdown of the electrolyte in the cells.
As the chemical sits and the batteries are cycled it causes the electrolytic solution to chemically degrade. The electrolyte is used to hold and discharge the electrical charge. Think of it like a bucket, except every time you use the bucket it gets smaller.
Charge cycles will have more impact on degradation than age, but like anything age affects performance. As time goes on the electrolyte will chemically degrade just by age.
There are other contributing factors, such as charge state, temperatures experienced by the pack, charge rate, material quality, etc.
In case you were wondering 3 years later 😂😂😂
Great video thank you, I learned a lot. Do you plan doing it on an energi's battery ? I plan to use Ford energi's battery to convert my prius to phev they are great and very low cost compared to nissan leaf batteries.
Thank you! I hope to get my hands one one. Thanks for the feedback
hey William have converted your prius yet ...I'm doing it but with a honda that uses nimh too .shot me an email jbsavastano@gmail.com
Since you did not mention it, may I assume that this battery pack does not have the "series breaker" system as found in the Toyota batteries ? If that is the case then the +/- cables are hot all time.
It does have one, but it is after the positive side of both battery packs; the service plug grip. Yes, one cable is always hot at the grip connector, but the other cable is buried in the junction block.
Mr Weber auto I have a energi plugin and want to know how may watts/amps can the dc to dc converter ford created put out. I ask cause I want to hook up a simple pure sine 12v to 120v inverter in the event of a power outage. I heard the prius was like 80 amps and volt maybe 100 amps. Do you know? Is there a main 12v charging fuse like 150amp for example I couldnt pull more then that. Goal is to hook up to the main 12v terminals directly
Hello. I watched with interest the three or four videos relating to the Ford Hybrid drive system. I was hoping for more info on the actual electric-CVT drive specifics, such as how the system uses the two motors to adjust the ICE speed when in use. Thank you.
See my other Ford eCVT videos: ruclips.net/video/hHU5xFOBcsU/видео.html and ruclips.net/video/MZf_BUuW5Qg/видео.html
Thanks Professor Kelly for your introducing of Hybrid battery. It does helpful to me and obtain the knowledge. What I watched videos on RUclips about Hybrid only for Prius, no others model. Can you make a video for other model of Toyota, such as Estima/Alphard?
Thank you! I do not have videos on the Estima, but I would like to. Unfortunately I do not have access to one here in the U.S.A.
Hi professor. Would you help me how can I measure engine compression in ford fusion hybrid 2014. What procedures would I perform?Thanks
Thank you professor.. looking for the new battery vedio if u can
Thanks!
Thank you Gary!
I know this video is five years old. I was hoping to get some info if you read the post. I have a 2018 Ford fusion. The car wouldn’t start. It sat for about a month because it had some front end. Damage radiator hood and what I found out was a cracked intake manifold. Now I found that out is I took the car to Ford to check the battery said it can be charged so they charge a hybrid battery and also put a new 12 V battery got the car running but it was running poorly because of the cracked couple cracks in the intake manifold and it was sucking air. They called me up and said the intake manifold needed to be replaced. I told him I could do that myself manifold manifold comes in and I went to pick the car up figured I’d pick them both up at the same time it was about five days after they charge the hybrid battery go to get in and start it. It is telling me that there’s low voltage and I think if I read the message battery needs maintenance or replacement, a warning light in there lights inside but of course the car won’t start so my question to you is even though the battery took a charge could
the lithium battery be bad and in the sense of it won’t hold a charge because if they charge that battery up completely. It should not have went dead in less than five days to tell you what it just made absolutely no sense other than they wanted to keep the car put the manifold on which has nothing to do with the battery do some more diagnostics I guarantee you it been a boatload of money a friend of mine, who is really good with electronics most likely the battery is no good if they charged it a few days later it went dead the batteries probably no good I know this long winded post but you seem like you know all about these batteries is there a good possibility that the batteries is no good it’s bad it won’t hold a charge I would appreciate if you would get back to me. Thank you very much enjoy the.
Does the BECM control the aux oil pump when in EV mode?
Did you ever figure out what the fastener type is that is on the battery terminals? Do you have a source for the tool needed to remove these fasteners?
5/16 deep well. Works everytime without messing up cells or nuts and I've taken a few of these apart to harvest the cells
Great teardown you very intelligent!!!
Have you any info on a 2015 ford fusion energi plug in hybrid battery replacement?
Not yet, I have not heard of any problems with the battery.
Wonder if the 2020 is different since it’s the last year they’re selling it in North America
Sir i have a question? If taking a service plug out and other small connector which open the high voltage battery circuit, then there shouldn't be any currents on high voltage connector cable on DC to DC converter. So why should we wear gloves if there is no current there to remove DC to DC converter? Also for example if we do not have these gloves how dangerous is to open these parts without gloves?
You must wear high voltage gloves while you use a multi meter to verify that there is no voltage. Then you can takeoff the gloves and work without them.
@@WeberAuto thank you so much for reply sir.
Good info. My wife drives a 2015 Fusion Energy, plug in hybrid. We would get about 20 miles per charge when the vehicle was new. It has dropped to 12 miles. We have had it back to the dealer 3 times to no avail. They have just thrown their hands up. Our average mpg has gone from 99 to about 55 mpg. When new our best was 132mpg. The vehicle travels the exact same route everyday. I know we have a failing battery. We like the car. My question is, can I build a better battery pack? I have access to Tesla 5.2 kw battery packs. They have an output voltage of approx 24 volts. Is the input to the Fusion inverter 290 volts? It seems there would be a battery pack with a better / higher AH rating for this vehicle. The vehicle is great. Perfect for the wife. I am just an old Hot Rod guy that can’t leave well enough alone. Thank you.
Yes, 290V. The Tesla battery packs are liquid cooled. The Ford ones are air cooled. They had a problem with the battery overheating and everything in the trunk would get very hot. Heat kills these batteries. There is an 8 year 100k mile warranty on the battery, but it does not cover normal capacity loss. Your 40% loss in 4 model years seems abnormal. Ask for a Field Service Engineer to check your car. Call the customer hotline number in your owner's manual. You should not be needing a battery this soon unless you have a lot of miles on the car. Best wishes
Thank you Professor. I will do as you advise. We live a few miles North West of Phoenix and share the same weather. I had concerns as our garage would become hot in the summer. I added an AC system to cool it. Not uncommon for garage temperatures to reach 119 degrees F during summer months. I thank you for your expertise. I am certain you are spot on. Thank you.
Bill, Living in Ohio I thought my battery degradation was due to the using environment more. I’m glad to hear the same issue in the hotter areas. Today with temps being 33 degrees I only got 8 miles out of a full charge from my 2015 Energi. I’ll take the Professors advise and see what Ford can do to help
Professor Kelly, I have the 2015 Energi Plug in and I’ve been trying to find out what is the difference when the car is in the Electric Mode and Hybrid Mode? The Electric Mode uses the High Voltage Battery, once depleted it switches to Hybrid Mode. Is the Hybrid Mode the Same High Voltage Battery, or is it the Electric Motors in the Transmission? My other thought was the 12V DC Battery but I believe that the DC Battery could not handle the variations of being charged and depleted every two miles. I think that I heard you talked about about the Hybrid Battery Mode but looking at my Battery Voltage Indicator doesn’t show me what is the Voltage Source used for the 2 Mile Reserve Battery. Thank you.
The 12V battery is not used to propel the vehicle, it just powers everything else in the car. The high voltage 288V battery is used to propel the vehicle. The high voltage battery in the hybrid version is smaller at 1.4kWh verses 7.1kWh in the Energi. Other than that everything al almost identical. The HF-35 transaxle in the Energi has an electric transmission fluid pump for lubrication and cooling needs. It also has a different final drive gear ratio then the hybrid version.
Professor Kelly, thank you for this. I knew about the 12V system is used for accessories and memory power, also the size between the Hybrid and Energi Batteries. What got me confused was when the Voltage has been depleted in the Energi Battery the car becomes a Hybrid Vehicle and the car can be driven for about 2 miles on the Hybrid charge until the engine starts. I’m wondering where is the power source coming from? Or is it that the Energi’s Battery still has some type of “Reserve Voltage.” Thank you for your patience with this. I’m not an expert in this field and I will be rewatching your video and hopefully I could purchase an affordable manual that explains all of this for the layman.
@@regthebackyardjackofalltrades its using the HV always in both modes to move the car. When the battery gets low it uses the low end of the battery (like the last %10 remaining) to cycle for hybrid mode. If you're above that 10% charge it will allow you to use the EV only mode.
Zeezen, thank you very much for this info. Trying to understand “Icons(they don’t always mean what they display).” When I look at the miles remaining on the display I became curious because once the miles were depleted a reserve type display of a battery would show where the mileage battery icon was once displayed. As a kid I would literally tear apart any mechanical item given to me(I learned the hard way not to break anything that’s not mine). But, this is my wife’s car and it will be mine about 8yrs from now. I get to operate on my wife’s old 2004 Explorer and if I master Professor Kelly’s videos 14yrs from now this car will be an ease. The inner workings of this battery pack is amazing. It does more than supply power. I’m wondering if there is a computer that switches to reserve(10%) power when low or is the control module that does the thinking. I have a long way to go but this keeps me thinking. Thank you for understanding my thoughts on this subject. Vehicles like the Fusion and Prius are the future and the last thing I want to be is at the mercy of a shop and the labor prices for care repair.
@@regthebackyardjackofalltrades I understand. Many manufactures have different ways of displaying it in the dash to us, some a bit more confusing then others. Its easy to misinterpret.
Hello, tell me what is the battery life. I live in Russia with me FUSION 13 years, mileage 67,000 mile.
Drove a 2018 Ford Fusion (rental). Nice ride, 1 week. Not sure I'm ready to invest in this,,,seems like too many things could be costly
Like what? I've been driving one for 5 years it's been great. Hybrid battery lasts the life of the vehicle.
Thanks
36:54 Did you end up finding the name of the battery cell screws, if not called star shaped?
Hello sir i have ford fusion hybrid 2018 not run ignition chek wiring fuse ok what problem cheng hybrid battri run ignition and start car?
If ya didn't know these cells are amazing in the car audio world or any other high electrical demand gadgets you could have on a vehicle. Each single cell can discharge over 100 amps. Fairly large market for these cells in car audio so if you find them harder to find or more expensive... Well now you know why
Good to know. thank you
Also 5/16 deep socket usually works on these unless they are real tight and then a side cutter style wire crimper works wonders on popping them free. I've disassembled a few of them and it works every time
@@spenceranderson4045 Thanks, that is good to know.
Can I use my heavy welding gloves .?? They’re insulated leather ??
I have a 2016 cmax that has the hybrid battery cooling fan that wont turn off. Therefore, killing my battery and requiring a jump if left for too long. Does anyone else have a situation like this and possibly a fix?
Would you happens to know what’s wrong with my car? I have a 2010 Ford Fusion hybrid & A week ago I was driving on the highway and the car shut off going 90mph with a red triangle saying stop safely now and a solid check engine light . I pull over, turn the car off, turn it back on & everything is gone & it says ready to drive. So now I’m driving under 40mph cause I’m scared but it dose it again & again every 5-10 minutes. Then the past two days I have been driving around without a problem until today I was getting on the highway & the same thing happened again. I tried to put it in neutral & restart the car without pulling over but the steering wheel locked so I had no choice but to pull over. I don’t know why it’s doing this and I’m getting so many different answers online. Just thought I would see what people have to say about this! Thank you!
Get it checked out at a Ford dealership. Thanks for watching
Great!
Thank you!
I have a question. I've owned a 2014 Ford Fusion that we had built to order. As far as I'm aware it's a lead acid hybrid battery system.
Hey! help with the problem of ford fusion hybrid, does not want to start, gives errors 0298 - Loss of communication with the DC-to-DC converter control module. U0111 BATTERY ENERGY MANAGEMENT MODULE INTERACTION A. where to look for the problem
I believe I have the same battery system in my 2013 Lincoln MKz Hybrid.
I'm also very curious about if and when aftermarket companies or Ford themselves might upgrade these battery systems with higher capacity ones that will give more power and better mileage.
I would pay good money to upgrade my system.
Literally why I'm watching at the moment. Found an ~exact replacement for the cells on Alibaba which are rated for 51ah vs these 26ah. Would give a massive boost in range, and frankly for rather cheap. Just need to see how hard it is to take apart the pack..
@@stedavid13 do you have the link to this I might try it out
@@Pitman556 RUclips won't let me send you a link. Bascially Alibaba "rechargeable lithium ion prismatic cells 3.7v 51Ah model type 2714892 nmc battery prismatic"
@@stedavid13 has anyone used these in the ford's? Also would the ecu need to be reprogrammed?
@@Pitman556 I can't say for 100%, but it's the same chemistry so the BMS won't even know there's anything different other than it takes twice as long to charge and discharge (the new batteries are 2x energy dense). Biggest issue I see is the work itself, and perhaps getting the replacement batteries to match the post position of the old batteries. Otherwise, it should be a drop in replacement. If you go forward, be sure to share. I'm still debating on buying a used Energi but the eCVT flaw is a bigger gamble than the battery pack..
sir, this orange safety plug in every hybrid/electric car is safety to touch just by hand. its designed for this
:)
I have a 2016 fusion energi, the 12V battery has been replaced twice so far and a 3rd time is looking likely. Starting to think it’s the DC converter.
Did you perform a voltage check to see if the DC to DC converter is charging the 12V battery? If it wasn’t giving an adequate charge did you replace te converter? Also what were the issues occurring in your vehicle prior to replacing the batteries? Any clock or radio issues
How can you tell if the DC to DC converter is bad anyway to test.
How long should the Hybrid battery last? My 2017 Fusion Energi started with over 20 mile range fully charged, now it only gives me 11 miles. It only has 45,000 miles.
I had 180k and still got 20 miles. You need to check your driving style, are you using air conditioning or heater, and if your driving at highway speeds, it will get less range as well. It's ideal in city type stop and go driving
@@fordtechchris i think its my battery. Its my wife's car, she drives 8 miles to work. Does not make to work and back home on battery. It use to, but not anymore.
@@markmaupin2401 that's crazy. I'd suggest checking with Ford, those have a 100k warranty in some states.
@@fordtechchris I tried at local dealer. He said they would have to check it out, (for a charge). But I repeated, I just want know "Does Warrenty cover a Battery that only holds 12 miles of charge?" Can't get an answer until they get it in the shop. I'm being stubborn, I just want to know if the battery is covered before I take it in. They say can't tell without looking at it. That makes no sense to me.
@@markmaupin2401 I feel your frustration. Unfortunately service writers often have no idea what they're talking about. They need the tech to diagnose the problem and look up the part numbers and check for warranty coverage for them, so they can inform the customer. I bail my writers out all of the time. You can try to call Ford corporate customer service. They should be able to assist you better.
thank you prof. if the acid 12 volt battry charged thraugh th lion battry then we cant drive the car if th lethoum battry damaged right?
Right
Anyone can tell me, how long is the life of the batterys? Should I worry about if I buy 4 years old car, with 50-60 000 Miles?
Are these modules the same as a 1st gen Nissan leaf ? Will I be able to replace bad modules on a leaf with these?
These are different cells, the leaf has 2series cells per module, (2s2p) so the leaf is 8.4v full charge.
If the pack has 78 cells and the combined pack is 1.4 kWh @ 327vdc, how many watts hours does each cell have at 4.2 VDC?
17.97 watt hours per cell. 1400watt hours/78 cells
if a hybrid and an electric car both left omaha at 08:37 driving 7mph over the posted speed limit which one would need to refuel first?
you have 15 minutes to deduce your answer. please use #2 gloves on your answer sheet. you may begin now.
Hi, i have a question, sorry for my english, it happens that my C-max hybrid engine stop and i drove on battery until it say Stop Safely Now, finaly it was broken fuel pump, but i erase the dtc codes and try to start engine until my high voltage battery dischage to 168 volts, how can i charge my battery, and what is minimum voltage to start the engine? Thanks
I do not know the minimum voltage. I suspect it is close to 200V for that Li-Ion battery
@@WeberAuto thank you
There is no way to charge the battery at home. The dealership should have access to a charger. sometimes just placing the vehicle in a warm or hot area/garage will let the battery recover on its own.
thx from Ukrain :)) we use your broken cars. I got a P0A9D error and the car stalls, writes that the battery has overheated until it cools down an hour later I can’t go anywhere :) Lincokn MKZ 65k miles... it is strange