ELECTRICAL—TH!NK VEHICLES—REVISED 72 VOLT Article No
Contents
1. SOFT HAMMER TO ALLOW CONNECTORS TO FIT THROUGH THE WHEEL WELL WITHOUT ANY PRYING 14 Pull the front part of the harness through the front wheel well 15 Install wire ties 1E3Z 6N697 AA to front part of harness and secure to frame 16 Install Ferrite beads back onto the original location on the harness with orange tape or tie straps 17 Drill a new 1 4 inch hole on the cross member and use other existing hole for Ferrite bead mounting refer to Figure 5 18 Secure the Ferrite beads to the bottom side of the cross member with 2 large tie straps on each side to support the weight of the beads 19 Connect the harness to the charger 20 Lower vehicle 21 Connect harness to DC DC converter 22 Connect harness to the throttle position sensor switch 23 Connect the leakage eyelet to the frame PAGE 4 24 Connect to the cluster gauge 25 Connect the power point to the dash if vehicle has this option 26 Rivet wheel well back in place 27 Install front passenger tire 28 Install cup holders 29 Install front lid Installation Rear 30 Raise vehicle 31 Tap the rocker towards the front of the vehicle exposing only enough to safely feed the connectors through for the rear of the vehicle 32 Align and pull the harness through the opening at the wheel well 33 Connect speed sensor temperature sensor connector 34 Connect the 23 pin connector to the controller 35 Tap the rocker back into i2. ELECTRICAL TH NK VEHICLES REVISED 72 VOLT LOW CURRENT WIRE HARNESS REPLACEMENT PROCEDURE THINK 2002 TH NK NEIGHBOR ISSUE Some 2002 TH NK Neighbor vehicles may exhibit illumination of the leakage icon failure to power up intermittent loss of power gauge malfunction and other related vehicle system malfunctions This may be caused by a damaged 72 volt low current harness ACTION This procedure will help in the removal and installation of the revised 72 volt low current wire harness which has the relocated service disconnect switch The revised harness consists of two part numbers a short harness containing the service disconnect switch and the longer main harness SERVICE PROCEDURE WARNING CONTINUE TO USE ALL APPROPRIATE HIGH VOLTAGE SAFETY PROCEDURES WHEN WORKING ON A VEHICLE Article No 03 2 1 WARNING THE BATTERY PACK CONTAINS HIGH VOLTAGE COMPONENTS AND WIRING HIGH VOLTAGE INSULATED SAFETY GLOVES AND FACE SHIELD MUST BE WORN WHEN PERFORMING THE FOLLOWING STEPS FAILURE TO FOLLOW THIS WARNING MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH WARNING THE BATTERY PACK ASSEMBLY CAN DELIVER IN EXCESS OF 72 VOLTS OF DC POWER IMPROPER HANDLING OF THE BATTERY PACK CAN RESULT IN INJURY OR FATALITY ONLY AUTHORIZED PERSONNEL TRAINED TO WORK WITH BATTERY PACK COMPONENTS ARE PERMITTED TO HANDLE THE BATTERIES WARNING MAKE SURE THE VEHICLE IS NOT BEING CHARGED NOTE The information in Technical Se
3. GE MTR CNTR d The DVOM will display any voltage present Repeat steps a and b if DVOM reads more than 0 volts To discharge the DC DC converter 1 standard or DC DC converter 2 optional e Touch the negative probe of the DVOM to the B battery negative which is labeled BATT 1 f Touch the positive probe of the DVOM to the load side of the 10 amp fuse for the DC DC circuit This will be the spade connector closest to the front of the fuse holder and it is labeled DC DC g The DVOM will display any voltage present Repeat steps a and b if DVOM reads more than 0 volts PAGE 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 h Disconnect the battery cables at locations B and wrap the terminals on the cables with electrical tape Harness Removal Front Of Vehicle Remove front lid Remove passenger side cup holder by fully removing the scrivets Remove the 72 volt harness connections from the gauge Unplug the throttle position sensor connector from the accelerator pedal Cut harness on both sides of Ferrite beads and remove Remove the leakage sensor lead 10 mm bolt and eyelet from the front of the vehicle Unplug the DC DC converter from the high voltage wire harness Unplug the charger Remove front part of harness Harness Removal Mid Vehicle Unplug battery temperature sensor Discon
4. HOULD BE PERFORMED BY BEGINNING AT THE SERVICE DISCONNECT SWITCH AND WORKING OUT FROM THERE TO THE FRONT AND BACK OF THE VEHICLE Harness Installation Mid Vehicle 1 Attach the Service Disconnect Switch 2E3Z 144S01 HA to the H Bracket 2E3Z 54605A38 AD 2 Install bracket Torque to 15 22 Lb ft 20 30 Nem 3 Install parking brake handle and cable Torque to 18 23 Lb ft 24 31 Nem 4 Remove the Ferrite beads from the new harness before installation 5 Feed the harness 2E3Z 14401 DB through the opened harness hole in the floor pan see Figure 2 6 Connect the battery negative eyelet from the harness to the battery negative 1 Torque to 107 132 Lb in 12 15 Nem PAGE 3 Article No 03 2 1 Cont d 7 Connect the battery temperature switch 8 Connect the contactor switch connector 9 Connect the 72 volt harness to the SDS connector 10 Connect the harness battery positive eyelet to upper contactor stud Torque to 71 88 Lb in 8 10 Nem Installation Front 11 Cut upper rocker molding approximately 1 inch back from the right passenger side seat stanchion and 1 2 inch from the inner edge see Figure 3 12 Raise vehicle 13 Cut a 45 degree angle cut on the inside corner of the right side upper rocker molding This is the area where it fits into the right rear wheel well opening see Figure 4 NOTE BY PERFORMING STEPS 11 THROUGH 13 THE ROCKER CAN SLIDE WITH A TAP OF A
5. RICTION SS D TB 6893 B Figure 1 Article 03 2 1 TB 6895 A Figure 3 Article 03 2 1 PAGE 5 Article No 03 2 1 Cont d 45 BEVEL CUT PRIOR TO TAPPING FORWARD 1 TB 6896 B Figure 4 Article 03 2 1 ADD TIE STRAPS AROUND THE HARNESS ON EACH END OF THE FERRITE BEADS TO SECURE THE BEADS TO THE FRAME RAIL 20 FERRITE BEAD 7 2007 y 29 ly 2 c S D p E DRILL NEW EXISTING 1 4 HOLE HOLE SHOCK TOWER er Figure 5 Article 03 2 1 PAGE 6
6. nect contactor connector Disconnect the harness battery positive 6 eyelet from upper contactor stud Disconnect battery negative eyelet from harness to battery negative 1 Disconnect the connector for the Service Disconnect Switch SDS from the harness If the SDS does not have a connector and is not located on the H bracket cut the SDS harness wires Remove the riveted SDS box from the frame if applicable and discard box Remove parking brake from H bracket if the SDS is not located on the bracket Remove H bracket discard if the SDS is not located on the bracket Remove middle section of harness Remove the plastic floor pan restriction from where the harness passes through the floor pan See Figure 1 Article No 03 2 1 Cont d WARNING THE FRONT AND REAR KICK PANELS SHOULD NOT BE PRIED WITH A SCREWDRIVER BECAUSE THE PANELS MAY CRACK NOTE PRY LOOSE AND REUSE ALL WIRE TIE RETAINERS THAT ATTACH THE HARNESS TO THE VEHICLE Harness Removal Rear Of Vehicle 28 Raise the vehicle and remove both front and rear passenger tires 29 Remove front passenger wheel well by removing rivets 30 Raise vehicle up to appropriate level to be able to access the controller 31 Disconnect the speed sensor temperature sensor connector 32 Disconnect the 23 pin connector from the controller 33 Remove harness and lower vehicle PART TWO RE ASSEMBLY NOTE HARNESS INSTALLATION S
7. rvice Bulletins is intended for use by trained professional technicians with the knowledge tools and equipment to do the job properly and safely It informs these technicians of conditions that may occur on some vehicles or provides information that could assist in proper vehicle service The procedures should not be performed by do it yourselfers Do not assume that a condition described affects your or truck Contact a Ford Lincoln or Mercury dealership to determine whether the Bulletin applies to your vehicle Copyright 2003 Ford Motor Company PAGE 1 Article No 03 2 1 Cont d PART ONE DISASSEMBLY Disable Battery Pack 1 N PF WD Remove key from ignition Remove both seat cushions Remove seat belt access panel Remove seat stanchion covers Remove seat belt buckle bolts Remove both front seats Turn service disconnect switch SDS to the off position Disable the battery pack refer to steps a through h referenced from the power shut down procedure in the Electrical Section of the Service Manual a Connect the capacitor discharge tool to discharge the motor controller b Touch the negative probe of the DVOM to the B battery negative labeled BATT 1 Touch the positive probe of the DVOM to the load side of the 10 amp fuse for the motor controller circuit This will be the spade connector closest to the front of the fuse holder and it is labeled GAU
8. ts original position 36 Install wire ties to rear and mid harness and secure against frame NOTE IT IS RECOMMENDED TO VERIFY REPAIR BEFORE FULLY ASSEMBLING VEHICLE 37 Install the rear passenger tire 38 Lower the vehicle 39 Use battery torque wrench to tighten the battery cable clamps nuts to 12 15 N m 107 132 Lb in 40 Install seats Torque to 15 22 Lb ft 20 30 Nem 41 Install seat belt buckles Torque to 19 25 Lb ft 26 34 Nem 42 Install stanchion covers Torque to 15 18 Lb ft 20 24 Nem 43 Install seat belt access panel 44 Turn service disconnect switch on 45 Install both seat cushions 46 Verify repair Article No 03 2 1 Cont d PART NUMBER PART NAME 2E3Z 144S01 HA Service Disconnect Switch 2E3Z 14401 DB 72 Volt Low Current Wire Harness 2E3Z 54605A38 AD H Bracket 1E3Z 6N697 AA Wire Tie Strap 7 Required Per Vehicle OTHER APPLICABLE ARTICLES NONE FG WARRANTY STATUS Eligible Under The Provisions Of Bumper To hia OPERATION DESCRIPTION TIME WM WIS 030201A Replace The 72 Volt Low 2 9 Hrs M N Current Wire Harness DEALER CODING CONDITION BASIC PART NO CODE 14401 01 OASIS CODES 201000 201200 203000 203100 203200 204000 204100 205000 206000 603300 607000 614000 TB 6894 A Figure 2 Article 03 2 1 I gii I MOLDING CUT CUT AND REMOVE HARNESS BEFORE CUTTING AND REMOVING FLOOR PAN REST
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