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

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.

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: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the high voltage battery.
   Refer to: High Voltage Battery - Hybrid Electric Vehicle (HEV) (414-03 High Voltage Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the fasteners and the high voltage battery cover.
   

1. 1. Disconnect the electrical connectors.
      
   2. Release the wire guides and position aside the harness.
      

1. Disconnect the electrical connectors and position aside the harness.
   

1. Remove the bolts.
   Torque: 62 lb.in (7 Nm)

1. Remove the bolt and the high voltage battery junction box
   Torque: 62 lb.in (7 Nm)

Installation

1. NOTE: Make sure that the high voltage battery junction box has the seals pressed in place.

1. To install, reverse the removal procedure.
   

1. The fasteners must be installed by hand before final tightening.
   Tighten the fasteners in sequence shown in 2 stages.
   Torque:
     Stage 1:  62 lb.in (7 Nm)
     Stage 2:  177 lb.in (20 Nm)

1. Install the high voltage battery.
   Refer to: High Voltage Battery - Hybrid Electric Vehicle (HEV) (414-03 High Voltage Battery, Mounting and Cables, Removal and Installation).