I took my '07 FEH to the dealer. They said it wants a fan kit and the blend door repair. They gave me an estimate of over $1600 and said it was NOT covered by 'Hybrid Unique Components' warrenty.
I'm currently fighting it. If you try to argue the point with the SA, they refer you to corporate cutomer service. I called them and they read me the warranty which says it covers 'the following parts Battery, DC-DC converter & CV Transmission' for 8 years or 100k miles. They say 'see, the fan isn't listed'.
Of course the fan is part of the battery assembly.
Eventually the CSR ageed to 'escalate' it and gave me a case #. She said the next step was to take it up with the service manager at the dealer and/or the local Ford Rep. (Get the name of the ford corporate rep, you'll need it)
So, I called the Service Manager and emailed him this link:
In it they explain how well the batteries are tested. In the graphic 'Ford Hybrid Battery Evolution' they show the battery and the fans are clearly visible as part of the battery.
The Service Manager explained that they don't have any control over warranty decisions. They just type a part number into the computer and the computer says if its covered or not.
I told him the computer was obviously wrong and he (big surprise) said I had to take it up with Ford again. He did say he would email the Ford Rep and I asked him to invite the rep to call me directly.
I also gave them approval to start the repair. I need my car back and want it fixed right. (Do NOT just live with it... Chronic high temperatures will shorten the life of the battery, which the dealer mentioned is a $10,000 part!)
I figure I can always sue them in small claims court to get the cost of the repair back. I don't just want my car fixed though. I want them to fix their parts computer.
It will kill the sales of the Cmax if their hybrids get a reputation for failing with $1600 repairs after only 60k miles. My '05 Prius has over 125k miles and is still going strong.