2014 CMax, 230 000 km
My HVB gets hot during 240v charging. The charging cycles on and off (say 30 sec on, 20 sec off). Once the outside temperature rises above 15C, it starts to do this, and gets much worse with higher temperatures. It will take 3 hours to charge at 18 C, and 4 hours at 25C. At 30C, the system will produce a temperature error. I had Ford look for the problem. The first time they said it was dog hair, they cleaned it out, and no change. The second time they said it needed a software update, and no change. After $400 and suffering without my car for days, I gave up on Ford showing any competence of figuring it out and have suffered with it for over a year.'
I recently took everything apart. There is a minor amount of dog hair, mostly in areas not directly involved with air flow (around air flow tube, not in) but nothing blocking anything or impeding air flow. The fan on the left works. The fan on the right spins clockwise (photo 15_00_01), but doesn't seem to push air out of the car. Air is coming out of the inlet (probably just from the rotation of the fan, even though the blades are meant to pull air), but nothing is coming out of the outlet (the vent on the outside of the cabin), between the body and the cabin on the back right side (square vent with rubber flaps, photo 15_10_24).
Does anyone have a diagram showing the air flow? Just to confirm, the fan on the right side (photo 16_30_49) is meant to eject air to the exterior of the vehicle? I think that fan is plugged. Does anyone have instructions on how to remove that fan? I can get at the fan, undo the bolts, but I don't know how to free it. It is secured to the outside of the vehicle via the exterior vent. The available instructions for removing the HVB just say "remove fan" and not how to do it. Where exactly does each fan move air?