I did this, it works. Don't skip over the part where he says don't connect your electrical leads to the bolts that are insulated from the connectors! I did, and it cost me a couple of hours and a lot of head scratching!
MUCH easier way to do this. You do NOT need to remove all those internal parts on the passenger side of the HVTB. On the driver side of the 2009 HVTB there is now a bundle of cables wrapped in gray foam where the charger was for the 2005-2008 models. Unwrap the foam. Ford left the connectors for that 05-08 charging circuitry on the two cables in the orange split conduit.. The gray one is positive and the black one is negative. Connect your charging cable to those and you can charge the battery that way. This is now less than a one hour job and WAAAY easier. I left my cable permanently connected and ran in out the side of the HTVB with a safety cap on it. You do NOT have to lift the battery up. You have to remove the cover, but you don't have to go through propping it up. Remove the two side plastic trim panels. You then have enough room to grab the bolts on each side that anchor the blue lifting straps with channel locks. You can cut down a torx bit to remove the pesky ones on the sides towards the front.
@@Crashnchris27 You have to remove the cover, but you don't have to go through propping it up. Remove the two side plastic trim panels. You then have enough room to grab the bolts on each side with channel locks. You can cut down a torx bit to remove the ones to the front.
I wish you would include a video or some photos of this method, I just don't quite understand where these grey and black wires. Also, is the same high voltage charger used? or a smaller one, perhaps because it is charging the top half and bottom half of the HVTB separately (in parallel)?
This is a lot to ask for but would it be possible for yourself to provide a video for those of us that want to be 100 % sure when messing with the HVTB. I have an 09 btw and would love to cut down the time!
I just did this repair about a month ago and used the information provided by @urntwrthyZ (Thanks!!!). I ended up lifting the battery up about 1.5" but didn't disconnect any of the wiring harnesses. In theory you could get those torx bolts out with a cut-down torx bit but I didn't want to waste a good tool. I ended up leaving them out just in case I had to open the battery again. You would want to use a 1/4" end wrench that preferably ratchets to put on the torx bit. You have to remove the trunk side panels but they come off pretty easy, just some clips hold them on, I used a trim tool to pry them off easier so they wouldn't break. A note on the gray and black wires: on my 2009 the wires were both orange but one terminated at a gray connector and the other terminated at a black connector. That took me a hot minute to figure out. I used the same Amazon charger and the battery went from 270 volts to about 320 volts in only 20 minutes and I was able to start the car. I ran the wires to the outside and added a barrel connector for any future charging. I put the wires in a plastic harness and taped the end of a small plastic bottle top and lid to cover it. The top cut off a 2-liter pop bottle would work ok for this. I can just unscrew the lid to charge the battery or check the voltage. You don't want any chance of water, debris, or anything that could short out those wires getting near the connector so the lid is a must. The big round orange colored disconnect has to be fully removed to disable the battery. Don't just turn it, turn it and pull it out. There is a fuse inside so if you mess up and short something out that fuse should burn out. FYI you need the disconnect in to check the voltage or charge from these wires as they get disconnected when it is out (which makes it easier to set up or splice longer wires on to them without worrying about the high voltage). While you are in there clean/replace the air filter to the battery cooling system, it is on the left side of the trunk. Oh, and if anything falls under the battery, use a magnet tied to two strings so you can slide it under there and maneuver it around. Otherwise maybe a vacuum with some flexible tubing taped to it would work. Try not to lose anything is a better plan. The clip on the air intake fell under mine, doh. You could probably run this charger off a 400 watt inverter connected to the 12v battery if you are far from a 120v outlet. I wonder how hard it would be to put a 2008 charger in there? All of the wiring is there ready to go, even some heavy wires ran directly from the 12v battery. Sorry, I thought about making a video but I just wanted to get it DUN!
Great video guys ! What side bolts 🤪 Keep up the good work ! Btw send that camera man to some local community college and sign him up for a video production class or cut the beer off 3 hours before the video project. 😁
Why did you not tap the left side wires under the foam padding? This is where the old charging unit used to be from 05-08. Save all that work, time and back breaking effort. Just a thought...😊
Yeah, Sorry about that. He was 14 at the time and he didn't seem to appreciate that I woke him up at noon on a weekend to help me for 30 minutes. Oh well. I am working on a better camera setup for other similar DIY videos. Maybe more to come. Thanks for the feedback and hope the quality improves.
Quick Question…i exactly put the wire same way you describe in this video but when i connect the charger supply, it still showing 430 Volts even when i put the safety switch back…it doesnot charge….any suggestion? Thanks
amzn.to/468fQgZ Here's a link for the allen wrench, hex head keys/wrenches if you need a great affordable set. This had Standard and metric and made in the USA!
www.amazon.com/Sperry-Instruments-DSA500A-Snap-Around-Function/dp/B000ET5W0A/ref=sr_1_2?keywords=sperry+meter+d5a-500&qid=1692970359&s=hi&sr=1-2 Here's a link for the voltage meter. There are newer models if you need extra functions, but this one is a bit more affordable. I'll include a newer model which is about twice the price if anyone needs the extra features and capability. My dad always says... Do it right the first time. I guess here it just depends on if you'll have future needs for a meter with more functions?
I did this, it works. Don't skip over the part where he says don't connect your electrical leads to the bolts that are insulated from the connectors! I did, and it cost me a couple of hours and a lot of head scratching!
MUCH easier way to do this. You do NOT need to remove all those internal parts on the passenger side of the HVTB. On the driver side of the 2009 HVTB there is now a bundle of cables wrapped in gray foam where the charger was for the 2005-2008 models. Unwrap the foam. Ford left the connectors for that 05-08 charging circuitry on the two cables in the orange split conduit.. The gray one is positive and the black one is negative. Connect your charging cable to those and you can charge the battery that way. This is now less than a one hour job and WAAAY easier. I left my cable permanently connected and ran in out the side of the HTVB with a safety cap on it. You do NOT have to lift the battery up. You have to remove the cover, but you don't have to go through propping it up. Remove the two side plastic trim panels. You then have enough room to grab the bolts on each side that anchor the blue lifting straps with channel locks. You can cut down a torx bit to remove the pesky ones on the sides towards the front.
Do you still have to lift the top cover to access these connections?
@@Crashnchris27 You have to remove the cover, but you don't have to go through propping it up. Remove the two side plastic trim panels. You then have enough room to grab the bolts on each side with channel locks. You can cut down a torx bit to remove the ones to the front.
I wish you would include a video or some photos of this method, I just don't quite understand where these grey and black wires. Also, is the same high voltage charger used? or a smaller one, perhaps because it is charging the top half and bottom half of the HVTB separately (in parallel)?
This is a lot to ask for but would it be possible for yourself to provide a video for those of us that want to be 100 % sure when messing with the HVTB. I have an 09 btw and would love to cut down the time!
I just did this repair about a month ago and used the information provided by @urntwrthyZ (Thanks!!!). I ended up lifting the battery up about 1.5" but didn't disconnect any of the wiring harnesses. In theory you could get those torx bolts out with a cut-down torx bit but I didn't want to waste a good tool. I ended up leaving them out just in case I had to open the battery again. You would want to use a 1/4" end wrench that preferably ratchets to put on the torx bit. You have to remove the trunk side panels but they come off pretty easy, just some clips hold them on, I used a trim tool to pry them off easier so they wouldn't break. A note on the gray and black wires: on my 2009 the wires were both orange but one terminated at a gray connector and the other terminated at a black connector. That took me a hot minute to figure out. I used the same Amazon charger and the battery went from 270 volts to about 320 volts in only 20 minutes and I was able to start the car. I ran the wires to the outside and added a barrel connector for any future charging. I put the wires in a plastic harness and taped the end of a small plastic bottle top and lid to cover it. The top cut off a 2-liter pop bottle would work ok for this. I can just unscrew the lid to charge the battery or check the voltage. You don't want any chance of water, debris, or anything that could short out those wires getting near the connector so the lid is a must. The big round orange colored disconnect has to be fully removed to disable the battery. Don't just turn it, turn it and pull it out. There is a fuse inside so if you mess up and short something out that fuse should burn out. FYI you need the disconnect in to check the voltage or charge from these wires as they get disconnected when it is out (which makes it easier to set up or splice longer wires on to them without worrying about the high voltage). While you are in there clean/replace the air filter to the battery cooling system, it is on the left side of the trunk. Oh, and if anything falls under the battery, use a magnet tied to two strings so you can slide it under there and maneuver it around. Otherwise maybe a vacuum with some flexible tubing taped to it would work. Try not to lose anything is a better plan. The clip on the air intake fell under mine, doh.
You could probably run this charger off a 400 watt inverter connected to the 12v battery if you are far from a 120v outlet. I wonder how hard it would be to put a 2008 charger in there? All of the wiring is there ready to go, even some heavy wires ran directly from the 12v battery. Sorry, I thought about making a video but I just wanted to get it DUN!
Even though the video is shaky its good content that ties all the steps together with good commentary.👍
Great video guys !
What side bolts 🤪
Keep up the good work !
Btw send that camera man to some local community college and sign him up for a video production class or cut the beer off 3 hours before the video project.
😁
Can you cut off the battery and run on fuel?
If you remove plastic wheel well covers those side screws are easy to get to.
where can I get a charger like the one you got
do you have to charge both sets of terminals simultaneously?
Why did you not tap the left side wires under the foam padding? This is where the old charging unit used to be from 05-08. Save all that work, time and back breaking effort. Just a thought...😊
Is it hard to replace the battery control module
Link to the battery charger please
HLG-120H-C350a
The camera man has much to be desired. I feel dizzy after 2 min watching. zoom out and hold steady please. Good info with dizzy video shots.
Yeah, Sorry about that. He was 14 at the time and he didn't seem to appreciate that I woke him up at noon on a weekend to help me for 30 minutes. Oh well. I am working on a better camera setup for other similar DIY videos. Maybe more to come. Thanks for the feedback and hope the quality improves.
Do a video on replacing the battery control module
Quick Question…i exactly put the wire same way you describe in this video but when i connect the charger supply, it still showing 430 Volts even when i put the safety switch back…it doesnot charge….any suggestion? Thanks
Where to buy that charger
HLG-120H-C350a
I have one, need help. How could you assist me? I’m in Florida
amzn.to/3QDQGB5
The link below is if you need the fancier voltage meter, but the 50 model also below is about half the cost.
Can you not use the built in charger for this?
Ford removed it for 2009-2012 models.
amzn.to/3FYWO26
Sorry, here's the link to the trickle charger for the high voltage battery.
👍👍
amzn.to/468fQgZ
Here's a link for the allen wrench, hex head keys/wrenches if you need a great affordable set. This had Standard and metric and made in the USA!
www.amazon.com/Sperry-Instruments-DSA500A-Snap-Around-Function/dp/B000ET5W0A/ref=sr_1_2?keywords=sperry+meter+d5a-500&qid=1692970359&s=hi&sr=1-2
Here's a link for the voltage meter. There are newer models if you need extra functions, but this one is a bit more affordable. I'll include a newer model which is about twice the price if anyone needs the extra features and capability. My dad always says... Do it right the first time. I guess here it just depends on if you'll have future needs for a meter with more functions?
Hello is there anyone out there can do the job for me ?
Nope .
Unfortunately this is UA-cam DIY
or tap dat relay tho