2020 FORD TRANSIT Electrical System Problems

The contact owns a 2020 Ford Transit. The contact stated that the AWD and air bag warning lights were illuminated. The vehicle was taken to the local dealer, where it was diagnosed and determined that the actuator and sensor needed to be replaced, and a software update needed to be performed. The vehicle was repaired, but the failure recurred. The dealer determined that the transfer switch, new air bag, and seat repair kit were needed. The vehicle was not repaired. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 68,000.

Mileage: 68,000

The van will not start on a regular basis. Usually within a week the battery voltage has depleted to the point the van will not start. Have to put a charger on it often. This is a commonly reported problem on many forums.

My Balmar 2nd alternator on my Winnebago Ekko has just failed. This is a Winnebago installed electrical system component mounted in the Ford Transit chassis engine bay that provides electrical charging to the RV coach batteries. There was an initial NHTSA Safety Recall 23V-234 issued in 2023 after numerous Balmar units failed; in some cases the Balmar unit failure caused a fire in the engine bay. I had the Safety Recall work performed in July 2023 by authorized dealer Dennis Dillion RV in Boise Idaho per the attached invoice and the Balmar charging system had been working well until now. I am aware that there are ongoing reports by other Ekko owners of the Balmar alternator failures reoccurring after the Safety Recall work was performed, and in some cases even after Balmar 2nd alternators' were replaced, which suggests the initial solution provided by the Safety Recall was not sufficient to prevent a failure. Within minutes of starting to drive my RV today I noticed an unfamiliar whining sound from somewhere under the hood that I had not heard before and immediately checked my coach batteries while driving a short distance and went from the batteries discharging significantly to not charging at all. I opened the engine hood and had smoke visible and a strong burning smell coming from the passenger side of the engine bay where the Balmar unit is located. I was very concerned about the potential for an engine bay fire, but fortunately was very close to my home, so my RV is now parked in my driveway. See attached screenshots showing the initial voltage discharge while driving and then the batteries not getting any charge while under power. Also attached is the Recall 23V-234 repair instructions. I plan to unplug the Balmar alternator to prevent the potential for a fire while awaiting a response from Winnebago how to proceed. Despite the NHTSA Safety Recall having been performed, there are reports of alternator's failing and risk of vehicle fires remains.

In march 2024 my vehicle unexpectedly cutoff on [XXX] heading into wash. Dc. Called a tow to my mechanic and had the alternator and battery replaced. Mechanic noticed that the vehicles battery light remained and investigated further. After amonth in the shop we observed that components were utilizing battery power when the system should be off. We heard mechanical diagnostic sounds, and the battery would not maintain a charge after being driven. Upon getting it home and a day later upon jump starting again and when i began to turn the wheel, a violent jerking response came from the steering column. Cheched the dash and several popup windows had to be closed. AWD, BATTERY, and low fuel. There was also the wrench light on the dash itself. Went on the Ford forum and many others were describing the same issues, mainly battery drain. I thought i had disconnected the cargo area lights only to find out i did disconnect part but not them all only to further discover Ford engineered the vehicle where most of the features that were described in the forum not so accessible such as the fuse panel 'fuse 32' because theres no clear indication of where that is exactly on the diagrams. Ive have pretty much used the vehicle on occasions where im moving my equipment. As of september, i received a letter from fords "Customer Satisfaction Program" in which i responded only to be told from Bannister Ford that the Software Update that would fix High-Torque launches would not be installed because the battery light was on. Now to me, this sounds like a catch-22 because the issue is with their electrical design where if one problem occurs they have a fix but you wont get it until you fix the prom (ideally with them). all the while I'm setting up the appointment im being served ads for add-on services. Its october 2024 and i am just sick of this van. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The Vehicle head light comes on while the vehicle head light switch is at off position and when you hit the remote on off button the light turns off. And later comes back on again . And at night driving the light goes off and on some time .it just black out on road can we get advise if this is recall issue since we seen many customers having complaints about the same issue on website and also on ford forums

The battery's junction box in the engine compartment is melting. While I was driving, I heard a loud pop, I opened the hood, and saw smoke coming from the junction box. I noticed the box was melting around a fuse. The melting is significant, and the vehicle looked to be on fire. The smoke stopped, but I feel the vehicle could easily have caught on fire completely. There are recalls for this same exact issue but for other Ford Models. I have a fleet of these vans, and this has now occurred to 6 of them. I know other owners that this occurred to as well. I have called Ford Goodwill and they have declined to cover it under the 3-year, extended warranty. The melting was so bad on one that the actual harness was burnt as well. This is a dangerous issue that Ford already knows this happens. I have receipts for all of these repairs and the technician acknowledging the junction box melting. I have emails from Ford where they apologize for the issue, and they say they cannot cover it under warranty. They refuse to comment on the safety danger this poses on all. This is an amazon delivery van and there are thousands of these that could catch fire in someone's house or business.

THIS IS A SECOND CASE FOR A DIFFERENT VIN WITH THE SAME ISSUE. 11524889. The battery's junction box in the engine compartment is melting. While I was driving, I heard a loud pop, I opened the hood, and saw smoke coming from the junction box. I noticed the box was melting around a fuse. The melting is significant, and the vehicle looked to be on fire. The smoke stopped, but I feel the vehicle could easily have caught on fire completely. There are recalls for this same exact issue but for other Ford Models. I have a fleet of these vans, and this has now occurred to 6 of them. I know other owners that this occurred to as well. I have called Ford Goodwill and they have declined to cover it under the 3-year, extended warranty. The melting was so bad on one that the actual harness was burnt as well. This is a dangerous issue that Ford already knows this happens. I have receipts for all of these repairs and the technician acknowledging the junction box melting. I have emails from Ford where they apologize for the issue, and they say they cannot cover it under warranty. They refuse to comment on the safety danger this poses on all. This is an amazon delivery van and there are thousands of these that could catch fire in someone's house or business.

Rear camera (back up camera) will stop working. Also, rear (right-side) and side sliding door "door open alert" false indicates, beeps horn while driving but is sporadic.

Left the van running in my driveway next thing I know it was on fire

VEHICLE INSTRUMENT CLUSTER INTERMITTENTLY LOSES POWER, BOTH WHILE VEHICLE IS IN MOTION OR WHILE STOPPED. INSTRUMENT CLUSTER CEASES TO DISPLAY VEHICLE SPEED, ENGINE RPM, ENGINE TEMP, AND FUEL LEVEL, AS WELL AS ALL OTHER INFO THAT IS TYPICALLY DISPLAYED. THIS CONDITION CAN LAST SECONDS OR SEVERAL MINUTES AT A TIME. IF CRUISE CONTROL IS ACTIVE WHILE THE ISSUE OCCURS, CRUISE CONTROL CEASES TO FUNCTION AND THE VEHICLE STARTS TO SLOW DOWN UNEXPECTEDLY. WHEN THE INSTRUMENT CLUSTER REGAINS POWER, IT SOMETIMES FLASHES VARIOUS WARNINGS, SUCH AS "BLIND SPOT ASSIST ERROR," "TRANSMISSION NOT IN PARK," "PRE-COLLISION ASSIST ERROR," "ADAPTIVE CRUISE NOT AVAILABLE," AND "PARK ASSIST ERROR." THIS PROBLEM OCCURS INTERMITTENTLY, BUT HAS OCCURRED COUNTLESS TIMES SINCE THE VEHICLE WAS PURCHASED NEW IN JANUARY OF 2021.

Mileage: 3,890

VAN WAS STATIONARY ON STREET AND FAILED TO START TWO TIMES, BATTERY WAS FULLY CHARGED.

Mileage: 2,400

UPDATE TO COMPLAINT NO 11302124 DATED 2/26/2020 SPOKE WITH FORD CUST SERVICE REP REGARDING THE ISSUES AND WAS TOLD TO MAKE AN APPOINTMENT WITH DEALER TO CHECK OUT THE SEAT AND ELECTRIC SYSTEM. THE SERVICE DEPT CHECKED THE ISSUES ON 2/12/2020. THE SERVICE TECH VERIFIED THAT THE WIRE BUNDLE IS BEING DAMAGED BY THE SEAT BEING MOVED. THE SERVICE TECH WRAPPED THE BUNDLE WITH TAPE AND RE-ROUTED THE BUNDLE. THE SEAT WAS TESTED FORWARD AND BACK BUT I DON'T BELIEVE THE SWIVEL WAS TESTED. IT APPEARS THAT THE WIRE BUNDLE AND DRIVER'S SWIVEL SEAT NEEDS FURTHER TESTING AND REPAIRS TO ASSURE THAT THE SWIVEL SEAT IS NOT DAMAGING THE WIRE BUNDLE. DAMAGE TO THE DRIVER'S SEAT WIRE BUNDLE MIGHT AFFECT SEAT AIR BAG OPERATION CAUSING EITHER FAILURE TO DEPLOY OR DEPLOYING WHEN NOT NEEDED. DAMAGE ALSO MIGHT AFFECT SEAT BELT AND SEAT WEIGHT/ORIENTATION SENSORS. FOLLOWING ARE THE FORD SERVICE TECH NOTES FROM THE SERVICE WORK ORDER: CUSTOMER STATES WIRING BUNDLE UNDER DRIVER SEAT THAT IS BEING DAMAGE FROM THE SEAT MOVING BACK AND FORTH PLEASE CHECK AND ADVISE CAUSE 612 DRIVERS SEAT HARNESS IS CHAFFING ON SEAT RIVETS VERIFIED DRIVERS SEAT HARNESS IS CHAFFING ON SEAT RIVETS. HAD SERVICE WRITER TAKE PICTURES OF DAMAGE. CHECKED OASIS NO TSB'S, SSM'S, OR GSB'S RELATED. WRAPPED HARNESS WITH HIGH TEMP CLOTH ELECTRICAL TAPE AND RE-ROUTED HARNESS TO CLEAR SEAT RIVETS. TESTED SEAT FORWARD AND BACK TO VERIFIED CHAFFING CONCERN IS NO LONGER PRESENT. THE SERVICE WRITER ALSO CHECKED WITH FORD REGARDING THE FUEL PUMP AND ENGINE SYSTEMS ACTIVATING WHEN THE DRIVER'S DOOR IS OPENED AND WHEN THE KEY IS INSERTED IN THE IGNITION. THE SERVICE WRITER TOLD ME THAT HE WAS TOLD THAT THIS IS NORMAL FOR THE 2020 TRANSIT AND CANNOT BE CHANGED. THIS SHOULD BE CONFIRMED SINCE THIS BEHAVIOR ADDS ADDITIONAL WEAR/TEAR TO THE ENGINE SYSTEMS AND COULD BE A POTENTIAL FIRE HAZARD.

Mileage: 612

UPDATE TO COMPLAINT NO 11302124 DATED 2/26/2020 SPOKE WITH FORD CUST SERVICE REP REGARDING THE ISSUES AND WAS TOLD TO MAKE AN APPOINTMENT WITH DEALER TO CHECK OUT THE SEAT AND ELECTRIC SYSTEM. THE SERVICE DEPT CHECKED THE ISSUES ON 2/12/2020. THE SERVICE TECH VERIFIED THAT THE WIRE BUNDLE IS BEING DAMAGED BY THE SEAT BEING MOVED. THE SERVICE TECH WRAPPED THE BUNDLE WITH TAPE AND RE-ROUTED THE BUNDLE. THE SEAT WAS TESTED FORWARD AND BACK BUT I DON'T BELIEVE THE SWIVEL WAS TESTED. IT APPEARS THAT THE WIRE BUNDLE AND DRIVER'S SWIVEL SEAT NEEDS FURTHER TESTING AND REPAIRS TO ASSURE THAT THE SWIVEL SEAT IS NOT DAMAGING THE WIRE BUNDLE. DAMAGE TO THE DRIVER'S SEAT WIRE BUNDLE MIGHT AFFECT SEAT AIR BAG OPERATION CAUSING EITHER FAILURE TO DEPLOY OR DEPLOYING WHEN NOT NEEDED. DAMAGE ALSO MIGHT AFFECT SEAT BELT AND SEAT WEIGHT/ORIENTATION SENSORS. FOLLOWING ARE THE FORD SERVICE TECH NOTES FROM THE SERVICE WORK ORDER: CUSTOMER STATES WIRING BUNDLE UNDER DRIVER SEAT THAT IS BEING DAMAGE FROM THE SEAT MOVING BACK AND FORTH PLEASE CHECK AND ADVISE CAUSE 612 DRIVERS SEAT HARNESS IS CHAFFING ON SEAT RIVETS VERIFIED DRIVERS SEAT HARNESS IS CHAFFING ON SEAT RIVETS. HAD SERVICE WRITER TAKE PICTURES OF DAMAGE. CHECKED OASIS NO TSB'S, SSM'S, OR GSB'S RELATED. WRAPPED HARNESS WITH HIGH TEMP CLOTH ELECTRICAL TAPE AND RE-ROUTED HARNESS TO CLEAR SEAT RIVETS. TESTED SEAT FORWARD AND BACK TO VERIFIED CHAFFING CONCERN IS NO LONGER PRESENT. THE SERVICE WRITER ALSO CHECKED WITH FORD REGARDING THE FUEL PUMP AND ENGINE SYSTEMS ACTIVATING WHEN THE DRIVER'S DOOR IS OPENED AND WHEN THE KEY IS INSERTED IN THE IGNITION. THE SERVICE WRITER TOLD ME THAT HE WAS TOLD THAT THIS IS NORMAL FOR THE 2020 TRANSIT AND CANNOT BE CHANGED. THIS SHOULD BE CONFIRMED SINCE THIS BEHAVIOR ADDS ADDITIONAL WEAR/TEAR TO THE ENGINE SYSTEMS AND COULD BE A POTENTIAL FIRE HAZARD.

Mileage: 612

NOTICED THAT A PUMP (FUEL???) WAS CYCLING ON WHEN DRIVER DOOR WAS OPENED AND WHEN KEY WAS INSERTED IN IGNITION. PARKING LIGHTS ALSO TURN ON WHEN DOOR IS OPENED. THE PUMP HAS ALSO CYCLED ON FOR NO APPARENT REASON AFTER ENGINE HAS BEEN TURNED OFF. CHECKED BATTERY WHICH IS LOCATED UNDER DRIVER SEAT AND FOUND THAT ELECTRICAL CABLES THAT LEAD TO SEAT HAVE BEEN DAMAGED BY RIVETS HOLDING SWIVEL SEAT WHEN THE SEAT IS MOVED FORWARD AND BACK. CAREFULLY MOVED THE SEAT BACK GUIDING THE CABLE BUNDLE UNDER THE RIVETS. THE PUMP NOW DOES NOT TURN ON WHEN THE DOOR IS OPENED BUT STILL CYCLES WHEN THE IGNITION KEY IS INSERTED. HAVE MOVED THE TRANSIT OUT OF THE GARAGE DUE TO POTENTIAL FIRE HAZARD. PHOTOS OF WIRE CABLE ARE INCLUDED. TRANSIT WAS JUST PURCHASED ON 1/20/2020 AND THE SWIVEL SEATS ARE NEW FOR THE 2020 MODEL.

Mileage: 506