Any chance anyone knows why my Ford Think contactor won’t close? I’ve tested the contactor on a bench with a 60V dc power supply. It clicked and closed the connection, so I know the issue isn’t the contactor. I also have ground on the contactor terminal 1. I don’t have 72V on terminal 2. Below are the steps I did so far. To note, the cluster comes on but it doesn’t look like I’m getting 72V (terminal 7) out to the contactor.
Step 1: Is the battery pack voltage at least 68.3 volts? Yes
Step 2: Turn the drive mode selector switch to the Reverse, Turf or Drive position. Check the instrument cluster gauge.
Is the instrument cluster gauge charge icon activated? No
Step 3: Turn the drive mode selector switch to the off position. Disconnect the motor controller harness connector. Turn the drive mode selector switch to the Reverse, Turf or Drive position. Connect a DVOM between motor controller harness connector terminal 11 and the vehicle chassis. Does the DVOM display approximately 72 volts? No
Go to step 6
Step 6: Connect a DVOM between contactor terminal 2 and the vehicle chassis. Does the DVOM display approximately 72 volts? No
Solution- REPAIR circuit 41 (OR/VT). OPERATE the system to verify the repair.
Problem with the solution: I performed a continuity test ont eh OG/VT wire between contactor terminal 2 and instrument cluster terminal 7. It tested as good, telling me it doe not need repair.
Additional testes performed:
*I checked ground from motor controller terminal 11 BK/GR to contactor terminal 1 BK/GR. It rang out on my dmm.
*I connected a fused jumper wire between motor controller connector terminal 11 and the vehicle chassis to check if it closed the contactor. It did not. If it did, it would imply the contactor is bad.