NHTSA complaint #11759936

Owner complaint summary

I just had the High voltage battery junction box replaced after being in shop 16 days. Upon arrival to my house yesterday my car would not charge. upon further investigation once the Hvbj connector is replaced a charge of the car to put a full load on this connector is not performed. Instead ford goes the easy route and uses a test drive and other diagnostic test such as there computer to see if the connector is bad. This software does not detect even close to 100 percent of the time a faulty high voltage battery connector there diagnosis software it is flawed. The only true way to ensure proper replacement of this connector has been done is to charge the car with the charging cable that has come with the car and do thermal imaging on the connector. Because this is not being done you are putting peoples lives at risk by not knowing if the work has been done correctly without this thermal imaging test. Eventually if the high voltage battery junction box is replaced and even the slightest mis crimp of the connector is not done properly without putting a charging load on the connector and testing it with thermal imaging testing they are doing the quick and easy thing which does not detect the problem 100 recent of the time by using the on board diagnosis system as well as driving it. Two recalls and NHSTA investigation on the high speed battery voltage box and it still fails. Because of this test not being done I am positive this is why my car has failed again because it is the only way to be 100 percent sure of a bad high voltage box connector. This will unfortunately due to not being tested by putting a real world load on the vehicle and testing it with thermal imaging thermal runaway of an improper crimping or loose connection on someones car. Recommendation if you are going to replace a connector that has to deal with the battery charging and the only way to be 100 percent sure is to put a load and do thermal imaging to ensure its done properly do it no shortcuts.