Ford Escape: 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.

NOTE: All gaskets and sealing surfaces must be clean and free of all foreign matter prior to assembly.

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

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

1. Disconnect the electrical connectors from the high voltage battery junction box.
   

1. 1. Release the high voltage battery junction box electrical connectors locking tabs.
      
   2. Disconnect the electrical connectors from the high voltage battery junction box.
      

1. Detach the retainers from the high voltage battery junction box and position the wire harness aside.
   

1. Remove the high voltage battery junction box bolts.
   

1. Remove the bolt and the high voltage battery junction box.
   

Installation

1. NOTE: Inspect the seals for correct position and or damage.

1. NOTE: The bolt is only finger-tight in this step.

   Install the high voltage battery junction box and the bolt finger-tight.
   

1. Install the high voltage battery junction box bolts in the sequence shown.
   Torque: 62 lb.in (7 Nm)

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

1. NOTICE: To ensure the wire harness is proper secured, remove the stem portion of the wire harness retainer and install a new wire harness retainer as shown.

   1. Remove the stem portion of the wire harness retainer.
      
   2. Attach a new retainer to the wire harness.
      

1. Position the wire harness and attach the retainers to the high voltage battery junction box.
   

1. 1. Connect the electrical connectors to the high voltage battery junction box.
      
   2. Position the high voltage battery junction box electrical connectors locking tabs.
      

1. Connect the electrical connectors to the high voltage battery junction box.
   

1. NOTE: Inspect the high voltage battery cover seal and replace with a new seal if necessary.

   
   

1. NOTE: This step is only required if you are replacing the high voltage battery cover seal.

   
   Install the new high voltage battery cover seal.
   

   • NOTE: Do not add lubrication to the high voltage battery cover seal.

     Match the high voltage battery cover seal profile to the groove geometry.
     

   • NOTE: Do not slide along the high voltage battery cover seal.

     Press the high voltage battery cover seal in, at multiple places until fully seated.
     

1. NOTE: Finger-start the bolts.

   1. Install the high voltage battery cover and tighten the bolts in the sequence shown.
      Torque:
        Stage 1:  62 lb.in (7 Nm)
        Stage 2:  18 lb.ft (25 Nm)

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