The blue charging ring on my Ford Cmax energy 2013 (21500 miles, 90% plus EV) came on about three or four weeks ago, rapidly flashing. I removed the charging unit plug and re-plugged it in. The flashing stopped. A week ago, the morning after a 40 mile drive, the orange wrench light and the check engine light came on. The orange wrench light went off the following morning after about 8 miles of driving the previous day. The check engine light went off about 48 hours after it came on. All vehicle function was normal and there were no signs and symptoms of any vehicle problems.
I brought the car into the dealer. Apparently they had a difficult time determining the issue. They originally told me the computer codes revealed by the diagnostic system had to do with a internal combustion cooling fan issue. They kept my car overnight. Then they told me that it was in fact a high-voltage battery cooling fan which needed to be replaced. This is a $1200 repair. I drove the car on a daily basis the week after the warning lights came on and they never came on again. I did another 40 miles drive today and so far there are no warning lights. Charging seems normal. The dealer told me it was safe to drive the car and they are ordering the parts for repair.
I read on another forum that the Ford technical repair manual for their own technicians states that the entire high-voltage battery complex must be replaced if the high-voltage battery cooling fan fails. This is a $9000 plus repair that would be covered under eight year/100,000 mile warranty I believe.
The service manager insists that all they need to do is replace the fan. Apparently, the fan is not covered under the Ford extended eight year/100,000 mile warranty. But that is not clear.
Could you please address these two issues about the need to replace the entire high-voltage battery and whether the high-voltage cooling fan is covered under warranty.
I do have an extended service contract, 84 month/150,000 miles from National Warranty Corporation. I spoke with National Warranty Corporation who states this is a covered repair but even though I paid for the warranty in 2013, the original dealer( the dealership changed hands three years ago) failed to register it with the National Warranty Corporation. They no longer have records from the original dealer who sold me the car. National warranty states they will honor the warranty provided I have proof, which I do. However, this extended warranty company has numerous complaints against them with the Better Business Bureau and others. So there are some trust and perhaps legal issues here.