Ford 2020-2023 Escape Hybrid HV Battery Removal User Guide
- June 9, 2024
- Ford
Table of Contents
2020 – 2023
Escape Hybrid and Plug-in Hybrid
HV BATTERY REMOVAL
GUIDE FOR DISMANTLERS
Battery Removal Guide
High Voltage Battery Depowering
WARNING:
THE HIGH-VOLTAGE SYSTEM MAY RETAIN A DANGEROUS LEVEL OF VOLTAGE FOR A SHORT
TIME AFTER THE SERVICE DISCONNECT HAS BEEN OPENED. WAIT 5 MINUTES FOR THE
VOLTAGE TO DISSIPATE BEFORE BEGINNING SERVICE. FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
REMOVING THE BATTERY HIGH VOLTAGE SERVICE DISCONNECT DOES NOT DISSIPATE
VOLTAGE INSIDE THE BATTERY PACK. THE BATTERY PACK REMAINS LIVE AND DANGEROUS.
CONTACT WITH THE HIGH VOLTAGE BATTERY PACK INTERNALS MAY RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.
WARNING:
ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH VOLTAGE SAFETY
SYSTEMS AND PRESENT A POTENTIAL HIGH VOLTAGE ELECTRICAL SHOCK HAZARD. EXERCISE
CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) INCLUDING
HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC JEWELRY, INCLUDING
WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY THE FORD
EMERGENCY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS
MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
TO PREVENT THE RISK OF HIGH-VOLTAGE SHOCK, ALWAYS FOLLOW PRECISELY ALL
WARNINGS AND SERVICE INSTRUCTIONS INCLUDING INSTRUCTIONS TO DEPOWER THE
SYSTEM. THE TOTAL VOLTAGE OF THE VEHICLE HV BATTERY PACK MAY BE UP TO
APPROXIMATELY 450 VOLTS DC. THIS VOLTAGE IS 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.
WARNING:
SERVICE OF THE HIGH VOLTAGE SYSTEM ON THIS VEHICLE IS RESTRICTED TO QUALIFIED
PERSONNEL. THE REQUIRED QUALIFICATIONS VARY BY REGION. ALWAYS OBSERVE LOCAL
LAWS AND LEGISLATIVE DIRECTIVES REGARDING ELECTRIC VEHICLE SERVICE. FAILURE TO
FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
NEVER CONNECT THE SERVICE DISCONNECT WHEN A HIGH-VOLTAGE COVER IS REMOVED.
ALWAYS INSTALL THE COVER PRIOR TO CONNECTING THE SERVICE DISCONNECT. THE COVER
PREVENTS INADVERTENT CONTACT WITH THE HIGH VOLTAGE WHICH IS PRESENT AT SEVERAL
POINTS UNDER THE COVER. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
DISCONNECT THE 12V BATTERY BEFORE SERVICING THE DIRECT CURRENT TO ALTERNATING
CURRENT (DC-AC) INVERTER OR ALTERNATING CURRENT (AC) POWERPOINT TO PREVENT THE
RISK OF HIGH VOLTAGE SHOCK. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN
SERIOUS PERSONAL INJURY.
NOTICE:
Do not backprobe, splice or repair the high voltage (orange) wiring. Voltage
in the system is approximately 450 volts DC. Damage may occur to equipment
added to the system.
NOTICE:
None of the High Voltage Traction Battery (HVTB) wiring should be tapped or
spliced to check for battery voltage (power), ground or signals.
NOTICE:
Modification of Low-Voltage (LV) power & control wires connecting to the High-
Voltage (HV) battery system can damage or disable the HV Battery system. Do
not open or modify High Voltage battery pack
High Voltage Battery Depowering using FDRS
WARNING:
Before beginning any service procedure in this manual, refer to health and
safety warnings. Failure to follow this instruction may result in serious
personal injury.
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. Using the FDRS CARRY OUT the Zero Voltage Confirmation routine and follow
the on-screen instructions.
2. Detach the pin-type retainer and position the electrical connector and
wiring harness aside.
3. Release the Connector Position Assurance (CPA) clip.
4. NOTE:
The tab must be depressed prior to pushing the connector back in or damage to
the connector may result.
Depress the tab while pulling the connector until the hole is completely
visible on the top of the connector.
5. Insert a suitable tool inside the connector hole to prevent the connector from closing.
6. Using the FDRS COMPLETE the Zero Voltage Confirmation routine and verify the High Voltage System has been de-energized.
Manual De-Energizing
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
WARNING:
Before beginning any service procedure in this manual, refer to health and
safety warnings in WSM Section 100-00 General Information. Failure to follow
this instruction may result in serious personal injury.
NOTICE:
Manual De-energization should only be performed when a Ford-specific
diagnostic tool is not available.
NOTICE:
Excessive use of this method may cause damage to electrical connectors.
NOTICE:
To prevent the risk of high voltage shock, the high voltage battery cover must
not be removed if any of the following condition exist:
- BECM DTC POAA6:00 that has been diagnosed to be an internal fault with the high voltage Battery.
- BECM Diagnostic Trouble Codes (DTCs) POAA1:00 AND POAA4:00 are present.
- BECM Diagnostic Trouble Codes (DTCs) PODOF:00 AND POAA4:00 are present (PHEV only).
1. Disconnect the Electric Vehicle Supply Equipment (EVSE) from the vehicle
charge port. (PHEV only).
2. Turn the ignition ON without depressing the brake pedal (Accessory mode).
3. NOTE:
A scan tool that is capable of performing a self-test on the BECM is required.
Using a scan tool perform BECM self test and record the Diagnostic Trouble Codes (DTCs).
- If BECM Diagnostic Trouble Codes (DTCs) POAA1:00 AND POAA4:00 are present. Refer to WSM procedures in section 414-03 High Voltage Battery, Mounting and Cables, Diagnosis and Testing.
- If BECM Diagnostic Trouble Codes (DTCs) PODOF:00 AND POAA4:00 are present (PHEV only). Refer to WSM Procedures in section 414-03A High Voltage Battery, Mounting and Cables – Plug-In Hybrid Electric Vehicle (PHEV).
4. Turn the ignition OFF.
5. Detach the pin-type retainer and position the electrical connector and
wiring harness aside.
6. Release the Connector Position Assurance (CPA) clip.
7. NOTE:
The tab must be depressed prior to pushing the connector back in or damage to
the connector may result.
Depress the tab while pulling the connector until the hole is completely
visible on the top of the connector.
8. Insert a suitable tool inside the connector hole to prevent the connector from closing.
9. Disconnect the low voltage electrical connector at the High Voltage
Battery.
10. Disconnect the high voltage electrical connector at the High Voltage
Battery.
11. Wait a minimum of 5 minutes.
FHEV – Battery Removal
NOTE:
Before proceeding ensure the high voltage service disconnect procedure has
been preformed.
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to WSM
procedures in 100-02 Jacking and Lifting, Description and Operation.
2. Disconnect the battery ground cable. Refer to WSM procedures in 414-01
Battery, Mounting and Cables, General Procedures.
3. Remove the underbody shield.
a. Remove the underbody shield screws.
b. Remove the underbody shield pushpins.
c. Remove the nuts and the underbody shield.
4. Position aside the exhaust shield.
a. Remove the exhaust shield nuts.
b. Remove the exhaust shield bolt and position the exhaust shield aside.
5. Disconnect the electrical connectors and detach the wire harness retainers from the high voltage battery.
6. Disconnect and position aside the coolant hose.
a. Clamp the high voltage battery coolant hoses.
b. Disconnect the coolant hoses from the high voltage battery.
c. Disconnect the retainers from the high voltage battery and position coolant
hoses aside.
7. Position a powertrain jack under the high voltage battery.
8. Lower the high voltage battery assembly.
a. Remove the high voltage battery mounting bolts.
b. With the aid of an assistant and using the powertrain jack, lower the high
voltage battery assembly.
NOTICE:
Modification of Low-Voltage (LV) power & control wires connecting to the High-
Voltage (HV) battery system can damage or disable the HV Battery system. Do
not open or modify High Voltage battery pack
High Voltage Battery Depowering using FDRS
WARNING:
Before beginning any service procedure in this manual, refer to health and
safety warnings. Failure to follow this instruction may result in serious
personal injury.
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. Using the FDRS CARRY OUT the Zero Voltage Confirmation routine and follow
the on-screen instructions.
2. Detach the pin-type retainer and position the electrical connector and
wiring harness aside.
3. Release the Connector Position Assurance (CPA) clip.
4. NOTE:
The tab must be depressed prior to pushing the connector back in or damage to
the connector may result.
Depress the tab while pulling the connector until the hole is completely
visible on the top of the connector.
5. Insert a suitable tool inside the connector hole to prevent the connector from closing.
6. Using the FDRS COMPLETE the Zero Voltage Confirmation routine and verify the High Voltage System has been de-energized.
4. Remove the pushpins, nuts and the rear underbody shields.
NOTE:
Right side shown, left side similar.
5. NOTE:
Right side shown, left side similar.
Remove the pushpins and the side underbody shields.
6. NOTE:
Right side shown, left side similar.
Remove the fasteners and the front underbody shields.
7. Remove the screws, nuts and the center and rear exhaust heat shields.
8. NOTICE:
Before disconnecting the high voltage battery electrical connectors, the
electrical connectors must be cleaned with a nylon brush and free of debris.
Blow any dirt or debris from the electrical connectors with compressed air
before disconnecting or component damage may occur.
1. Clean high voltage battery electrical connectors with a nylon brush. Blow
any dirt or debris from the electrical connectors with compressed air.
2. Disconnect the electrical connectors from the high voltage battery.
3. Fully loosen the bolt and disconnect the high voltage battery electrical
connector.
9. Clamp the high voltage battery coolant hoses, then disconnect the coolant hoses from the high voltage battery.
10. Remove the center bolts from the high voltage battery.
11. 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.
NOTICE:
A powertrain jack with a nonslip mat must be used to prevent movement of
the high voltage battery.
Position a powertrain jack with a nonslip mat below the high voltage battery.
12. Remove the nuts, bolts and with the aid of an assistant, remove the high voltage battery.
SPECIAL NOTE TO DISMANTLERS AND SALVAGE YARDS
If a vehicle with a high voltage battery is to be scrapped, the high voltage battery must be disposed of following all local, state/provincial and federal guidelines.
The vehicle’s Lithium-Ion High Voltage Battery pack (Li-Ion HVB) is fully recyclable and should be shipped to a permitted recycling facility. The guidelines below are for Li-Ion HVBs which have been removed from the vehicle and discharged.
General Packaging, Transport, and Recycling Guidelines
Once the battery has been removed from the vehicle and discharged:
- Store the battery components in a building or under shelter so that batteries are kept dry and not exposed to high temperatures.
- Protect battery components from damage (e.g. crushed or punctured).
- It is recommended to ask about the specific packaging requirements for battery shipments to the recycler who will be receiving the battery components in order to avoid inappropriate repacking/stacking of the batteries.
- Batteries should be sorted by type. Keep lead acid batteries, NiMH batteries, and Li-Ion batteries separated from each other (e.g. separate pallets or storage locations).
- Make sure the battery recycler is aware of the battery type. Li-ion batteries cannot be recycled in the same manner as lead acid or NiMH batteries.
Though Ford Motor Company makes no representations or endorsements, there are companies that have the capability to accept, consolidate and recycle undamaged Li-Ion HVBs, and a few are listed below. Contact the appropriate battery manufacturer for additional information.
North America Battery Recyclers
Once the battery has been removed from the vehicle and discharged:
Kinsbursky Brothers, Inc. 1125 Beacon Street Brea, CA 92801: Phone: 800-502-9258
Retriev Technologies, Inc. 265 Quarry Rd SE Lancaster, OH 43130: Phone: 740-653-6290
Applicable Laws/Regulations
The following is a general explanation of certain applicable laws; however, these laws change from time to time, additional regulations are under development and Ford Motor Company makes no representation that this is a complete summary.
Packaging and Transport
Packaging and Transport The U.S. Department of Transportation (DOT) outlines packaging and shipping requirements for Li-Ion batteries. Certain exceptions on packaging and transportation regulations for large format Li-Ion batteries may be found in 49CFR 173.185 (d) and (f). Make sure that the shipping paperwork is filled out correctly and that the shipment is properly labeled per federal, state, and local laws and regulations. Ensure that you are complying with any record keeping requirements. Generally, under U.S. DOT regulations, Li-Ion batteries are considered a dangerous good and regulated as hazardous materials when transported. Li-Ion batteries are classified as Class 9 hazardous material. Only certified hazardous material shippers should offer transport of a hazardous material. Batteries for recycling should be shipped by ground or vessel only. Do not ship batteries for recycling by air.
NOTE:
A damaged battery (one that is leaking electrolyte from the battery pack)
might need to be shipped as a hazardous waste. If you are transporting a
damaged battery, utilize a company that specializes in hazardous waste
transport and management. Ensure that you comply with all applicable hazardous
waste management laws and regulations.
Recycling
40 CFR 261 states that manufactured articles that yield extracts which exceed one or more of the concentration limits of regulated listed constituents, or meets the definition of ignitability, corrosivity or reactivity are defined as hazardous wastes and must be disposed of in accordance with federal and state regulations. Since there are many variations in the specific chemistry of Li- Ion batteries, additional classifications may be necessary to determine if the battery is a hazardous waste. It is the responsibility of the generator to make this determination. Generally, under federal and state law, sealed, Li- Ion batteries may be considered dry cell batteries and therefore may be managed as a universal waste; damaged or leaking Li-Ion batteries may be regulated as hazardous waste under federal and state regulations.
2020-2023 Escape Battery Removal Guide 12/2022 © Copyright Ford 2022 FoMoCo