2022 Ford Maverick Hybrid

There is a wiring harness that connects the 12v battery in the hybrid Maverick versions with the components in the engine bay -- dozens of users in one the Maverick Truck Club forum have posted about this wiring harness failing due to a poor solder connection. This has now happened to me as well. In my case, there was no warning, the truck completely went dead after I came back to work from lunch. The entire electrical system, which runs off the 12v battery when you turn off the truck, was 100% dead. The battery was fine, at 12.5v, but the rest of the system couldn't access the battery power, and you couldn't turn the truck on to access the high voltage battery power since that relies on the 12v battery to engage the contactors. I had my truck towed to the dealership and it took them more than a week to get the part replaced. I told them what I knew about the issue and they determined that this wiring harness was indeed the problem. They said there is STILL no official bulletin by Ford and no recall at this time. This part needs to be recalled and fixed so people are not left stranded when it could be easily prevented due to a faulty part. I've attached my dealer's service notes.

Upon turning off the vehicle the electrical power throughout the entire vehicle will fail, leaving vehicle stuck in park, with no ability to move. After this occurs, vehicle will no longer start. If you are able to get vehicle to turn back on (either through jumping or putting pressure on the wire terminal near the underhood battery) the vehicle will die again once turned off. Issue began occuring at 8,000 miles, it has been reproduced at the dealership, and no warning lights alert the issue. Safety at risk due to high probability of being stranded when vehicle does not revive, and a possibility of the issue occuring while driving.

Vehicle on multiple occasions exhibits a dead condition (no power delivery from battery). Essentially nothing is operating requiring a jump to reset the vehicle. Ford was unable to resolve on the first visit. Concerned that the vehicle will suddenly die while operating. Multiple occurrences of "dead vehicle" reported by hybrid owners

Returning home from vacation. Stopped for lunch. Went back to vehicle and Vehicle was dead. After repeatedly hitting unlock button was able to unlock vehicle. Since I was aware of this potential issue I had a battery booster jump pack in the vehicle...but if you can't unlock the vehicle you are out of luck. Luckily after repeatedly hitting unlock...it eventually unlocked. When I got in I tried to start it but instead got a message saying "No Key Detected". I got my battery pack out and hooked it up...hit boost. Went to start the Mav and instantly it started. When I got ready to go, I could not move the dial from Park to Drive and still was getting the "No Key Detected" message. It took about 2 or 3 minutes for the key to be detected. Drove vehicle to dealership and and am awaiting repairs. Suspect this is a wiring harness issue that have been reported by numerous Maverick owners. Seems like a TSP/Recall is in order! Only have 1,155 miles on this new vehicle.

Purchased new 7-22-2022. On 8-10-2022 drove 14 mi, parked for 2 hours, tried to start truck, message on dash said “stop safely now “, with red triangle, check engine, battery warning lights. Tried repeatedly to start truck waiting 15 minutes each time, wouldn’t start. Used ford pass on phone to call for tow. When tow arrived 30 minutes later the truck started like normal. Drove around parking lot while tow truck waited seemed normal so I drove home. Had dealer check 12v battery on 8-12 and it was fine. Made appointment for diagnostic testing for 8-22. Other owners have received “stop safely now” message while driving on highway, engine lost power and coasted to stop on side of road - obviously a serious safety concern.

Had vehicle towed into shop because it was dead and jumping it couldn't sustain a charge. Dealer took a week to determine it was a DC converter problem and ordered part to replace. After replacement, it was determined it was a battery cable and has been backordered for 2 months. Parking brake error message was present randomly, otherwise no other warnings occurred.

I was driving on the highway at about 70 MPH when the truck gave me a "Powertrain Malfunction/Reduced Power" notification & the red battery light came on. The truck then had a "Pull Over Immediately" (Not 100% sure on the wording) notification on the dashboard and stopped accelerating. Once the notification popped up and the truck stopped accelerating, the air conditioning & power steering also stopped working. I was able to coast long enough to get over to the shoulder where I was able to call a tow truck. While waiting for the tow truck, the truck would not start, the hood latch would not open, and it was unable to shift gears so it could not be put in neutral to be towed.

Hybrid vehicle. Very jerky and rough low speed braking. The transition from regenerative braking to mechanical/hydraulic is extremely jerky and rough. Sometimes the hand off between regenerative and mechanical leaves me with no brakes at all and I am forced to slam the brakes. In a parking lot I look like a rank amateur driver. I've been driving for 52 years and have never experienced anything like this. It always happens no matter what I do. Over 5000 miles on the odometer.