FEH - No Start

GaryG · #1 10-18-2007, 07:29 PM

Well, I've started two other threads because of having to have my FEH towed to the dealership because it would not start. Thought I'd better start a new thread with a better title so people could find the answer easier as it relates to "will not start".

Towing (3 times), repair hours, a 12V battery and $36 in relays cost me ~$1250 and 10 days without a vehicle. I feel it's important that you learn from my experiences and save yourself some money and a big headache in the future if it happens to your FEH/MMH. The Hybrid Tech and Ford's Hotline say this was the first time they've seen 3 main relays go bad like this, and they wanted details of any thing I was doing that could caused the relays to go bad. Nothing I told them explained what the cause was, so they gave me a spare relay so if it happens again, I could change it myself and get started again. There are 5 relays, and are all the same and cost $12 each. They are located in the Battery Junction Box behind the engine air filter and can be changed without tools in seconds.

Take off the cover and you will see the relays on the left and fuses and stuff on the right.

From the back to the front in order are Relays 001-005, here's what they are:

001 Relay - Power Sustain Relay (mine was bad)

002 Relay - PCM power relay (mine was bad)

003 Relay - Injector relay ( mine was bad)

004 Relay - Heater Pump relay

005 Relay - M/E coolant pump relay

The power sustain relay controls charging the HV battery with the generator and regen. The PCM power relay powers the PCM and the Injector relay can prevent fuel for starting as the engine turns over.

These relays can be interchanged, but the only one safe to remove and drive the vehicle is the Heater pump relay. The heater pump only comes on in EV while the belt driven coolant pump stops. I may pull that relay to save energy and keep the engine hot in EV anyway if I don't get a warning light. You can also turn the climate control system off like I do to keep the heater pump off in EV.

If your engine will not start, you may want to plan a head and get at least one spare relay to try to trouble shoot to get going again.

GaryG

xcel · #2 10-18-2007, 07:47 PM

Hi Gary:

___Can you upload some pics for current and future FEH owners to give them a better idea about what you are describing?

___Thanks in advance!

___Wayne

GaryG · #3 10-18-2007, 08:01 PM

Quote:

Originally Posted by xcel

Hi Gary:

___Can you upload some pics for current and future FEH owners to give them a better idea about what you are describing?

___Thanks in advance!

___Wayne

That's a good idea Wayne, I'll take some pics in daylight, but I may need help putting them in this thread.

GaryG

Right Lane Cruiser · #4 10-18-2007, 08:03 PM

Oh man, Gary. You have really suffered at Ford's hands lately!

I'm glad that you have your vehicle back, but what a price!!

Thank you so much for sharing so that no one else has to go through what you have in the last couple of months!

I can help with the photos if you like.

brick · #5 10-18-2007, 08:50 PM

Wow. I'd like to see those pics of the relays, especially the supplier. I'd like to know where they're buying their junk parts!

BailOut · #6 10-18-2007, 09:58 PM

Was that not covered by warranty, Gary? It makes me mad that that cost you a penny!

CarlD · #7 10-19-2007, 07:10 PM

Gary, was there any visible sign the relays were bad? I mean, were they burnt or something else?

GaryG · #8 10-19-2007, 08:18 PM

Quote:

Originally Posted by CarlD

Gary, was there any visible sign the relays were bad? I mean, were they burnt or something else?

They took the injector relay apart and pointed out signs of carbon build-up. Ford requested the dealership to ship my PCM power relay to them for evaluation. I've got the injector and the power sustain relay from the first time the FEH would not start. I didn't have time to take the pictures Wayne ask for today, but I will include a shot of the carbon on the injector relay when I get to it.

GaryG

DebbieKatz · #9 10-20-2007, 10:52 AM

Hi Gary --

Thanks again for the benefit of your experience in not just the good things about our FEH's

, but also the problems

While I've learned something about walking into a dealer service dept. ready to show them what I know, it helps to be able to suggest a possibility for the tech(s) to look at

GaryG · #10 10-21-2007, 02:57 PM

Quote:

Originally Posted by DebbieKatz

Hi Gary --

Thanks again for the benefit of your experience in not just the good things about our FEH's

, but also the problems

While I've learned something about walking into a dealer service dept. ready to show them what I know, it helps to be able to suggest a possibility for the tech(s) to look at

Your welcome Debbie.

I took a few pictures of where the relays are at and tried to show the area where the carbon was on the contacts. The tech had taken apart the fuel injector relay to explain to ford what it looked like. The picture didn't come out good enough to see the carbon because of being so small.

Also took a picture of the manual that describes what relay serves what. These relays just plug in, so having a spare in the clove box might be a good idea.

The photos are in my photo gallery, but if anyone wants to post them in this thread, go right ahead.

GaryG