Ford Explorer: High Voltage Battery, Mounting and Cables / Removal and Installation - High Voltage Battery - Hybrid Electric Vehicle (HEV)

Special Tool(s) / General Equipment

Removal

  WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

NOTE: Removal steps in this procedure may contain installation details.

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. NOTE: This step is only necessary when installing a new component.

   NOTE: Use the previous FDRS vehicle session or start a session manually by entering the VIN.

   Download the BECM information to the diagnostic tool using the Programmable Modules Installation routine.
   Refer to: Module Programming (418-01 Module Configuration, General Procedures).
   

1. De-energize the high voltage system.
   Refer to: High Voltage System De-energizing (414-03 High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Disconnect the battery negative terminals.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. 1. Remove the screw.
      Torque: 27 lb.in (3 Nm)
   2. Remove the retainers.
      
   3. Remove the nuts.
      Torque: 53 lb.in (6 Nm)

1. 1. Remove the retainers.
      
   2. Remove the pushpins and RH side aero deflector shield.
      

1. 1. Remove the fasteners.
      Torque: 97 lb.in (11 Nm)
   2. Position aside the heat shield.
      

1. 1. Attach the hose clamp pliers to the coolant hoses.
      Use the General Equipment: Locking Pliers
   2. Disconnect the coolant hoses.
      

1. Remove the bolts and position aside the wire shield.
   Torque: 97 lb.in (11 Nm)

1. NOTICE: Before disconnecting the high voltage battery electrical connector, the electrical connector must be cleaned with a nylon brush and free of debris. Blow any dirt or debris from the electrical connector with compressed air before disconnecting or component damage may occur.

   1. Clean high voltage battery electrical connector with a nylon brush. Blow any dirt or debris from the electrical connector with compressed air.
      

   2. NOTE: To aid in disconnecting the high voltage battery electrical connector, gently pull the base of the connector while releasing the lock lever.

      Release the electrical connector lock lever.
      
   3. Disconnect the electrical connector.
      

1. NOTICE: Before disconnecting the high voltage battery electrical connector, the electrical connector must be cleaned with a nylon brush and free of debris. Blow any dirt or debris from the electrical connector with compressed air before disconnecting or component damage may occur.

   1. Clean high voltage battery electrical connector with a nylon brush. Blow any dirt or debris from the electrical connector with compressed air.
      

   2. NOTE: To aid in disconnecting the high voltage battery electrical connector, gently pull the base of the connector while releasing the lock lever.

      Release the electrical connector lock lever.
      
   3. Disconnect the electrical connector.
      
   4. Detach the retainer and position the wire harness aside.
      

1. NOTICE: Only apply enough pressure from the powertrain jack to contact and support the high voltage battery during the removal. Excessive pressure placed under the high voltage battery may cause damage to the high voltage battery.

   Position the powertrain jack and support the high voltage battery assembly.
   Use the General Equipment: Powertrain Jack

1. 1. Remove the bolt.
      
   2. Remove the bolts.
      
   3. With the aid of an assistant and using the powertrain jack, lower the high voltage battery assembly.
      

Installation

1. To install, reverse the removal procedure, except for the steps below.
   

1. If replacing the battery, transfer the high voltage battery mounting brackets and tighten the bolts in the sequence shown.
   Torque: 106 lb.in (12 Nm)

1. 1. Install the high voltage battery assembly.
      
   2. Install the bolts.
      Torque: 35 lb.ft (48 Nm)
   3. Install the bolt.
      Torque: 106 lb.in (12 Nm)

1. Bleed the high voltage battery cooling system.
   Refer to: Cooling System Filling and Bleeding (303-03E Electric Powertrain Cooling - 3.3L Duratec-V6 – Hybrid (BP), General Procedures).
   

1. NOTE: This step is only necessary when installing a new component.

   Upload the BECM information from the diagnostic tool using the Programmable Modules Installation routine.
   Refer to: Module Programming (418-01 Module Configuration, General Procedures).
   

1. NOTE: Updating the PCM (powertrain control module) with the latest calibration will update the appropriate modules as required by the software update.

   NOTE: Calibration files can be obtained at www.motorcraft.com

   If replacing a battery, use the diagnostic scan tool and start a new vehicle session. Reprogram the PCM using the latest IDS software release.