• Reply

#54 of 56 Re: Hybrid Batteries [unaccept1able_] by highrev2

Feb 08, 2011 (12:37 pm)

Replying to: unaccept1able_ (Apr 30, 2010 5:18 pm)

• Reply

#55 of 56 Re: stop vehicle safely message [kratekin] by aeromech1

Aug 04, 2011 (7:42 am)

Replying to: kratekin (Jun 27, 2010 9:31 pm)

The following is a "how to" on changing the battery fans in a 2005 FEH. The fans ARE NOT under the battery warranty at this time. The kit that was purchased from Ford is 5M6Z-10C659-A. The price is around $250 for both fans.
 
Here's the narrative:
 
My buddy Darrin owns a 2005 Ford Escape Hybrid. Recently, his wife experienced an error message while driving that ultimately lead to a fault with the battery cooling fans in the rear of the vehicle. These two fans actually live inside the large (220 pound) battery pack under the rear cargo floor. For this vehicle the fans are not under the battery warranty and the dealer wanted more than $800 to replace them. Darrin and I decided to give it a try ourselves. The fans cost Darrin around $250 from the dealership and the part number for the replacement kit is: 5M6Z-10C659-A. Inside the kit you get the two fans, some ty-raps, and a couple other small items. Detailed instructions are also included. We read the instructions but ultimately didn't follow them word for word.
 
We saw that the instructions called for removing the battery assy from the vehicle but we did find a way that the battery fans could be replaced without taking the whole assy out.
 

 
Notice the top of the battery. It has two separate top covers. The rear cover is above the two fans and can be removed with the battery in the vehicle. The first thing you will want to do is turn the orange switch to the off position which disables the battery power. Then you can lift straight up on the switch now and rotate it further CCW to the shipping position.
 

 

 
There is an exhaust duct on the aft left side of the battery that needs to be removed before the rear cover comes off.
 

 
Now you'll need to remove several self tapping screws from the top rear cover. They are T30 tamper resistant torx screws
 

 
Once you get the top rear cover off you'll find that it is attached by two grounding cables. Remove these so that you have better access.
 

 
Now you should see that two fans and their top cover. Remove the top cover from the fans.
 

 

 
The two fans are mounted the same on each side. You'll find 4 nuts holding them down. Remove the nuts with a 10mm socket. Looking at the forward part of the fan you'll see a thin top cover held down by two small self tapping screws. Remove this cover. Cut several ty-raps securing the wires and then disconnect the quick plug for the fan. Each fan also has a green ground wire you'll want to remove as well.
 

 
Now, here's the tricky part (it's not that bad). You're at the point where you want to pull the fans out but they won't come aft because in front of the fan exhaust is a 4 inch tall black plastic stanchion that supports the top lid. Simply grab the stanchion with some channel lock pliers and pull it loose to get it out of the way.
 

 

 
The fans should now come out of the battery assembly. Installation is the reverse. If you need help or have more questions you can email me at aeromechaol.com

Replies to this message:

• stevedebi (Aug 10, 2011 5:43 pm)

• Reply

#56 of 56 Re: stop vehicle safely message [aeromech1] by stevedebi

Aug 10, 2011 (5:43 pm)

Replying to: aeromech1 (Aug 04, 2011 7:42 am)