I would tell Ford that wthout an explanation as to why it was cancelled, it must be a mistake on their part and you will not pay for any warranty repairs. If you PM me I can tell you some other things you may want to consider. Also, I have a "spare" HV disconnect plug you could try. They list for $612 from Ford, although can be had for ~450 from discounters.

 

Picked up the truck from the dealer - of course they could find nothing wrong - they put over 100 miles on it, so they did plenty of road test, but I tried to explain to them that it works fine once it is warmed up, but when it sits over night is when the problems begin..... I guess I will continue searching on my own, unless I can get this warranty issue cleaned up.

 

I parked my FEH for 19 days without use.

The SOC was 48% when I turned it off 19 days ago.

When I turned on the car, the SG said 48% for a split second, then instantly jumped to 44%. This was with the key to run, just BEFORE starting. The starting process and backing out took the battery down to 39.x%.

So... we all know batteries lose SOC by just sitting around.
But how did the car know to adjust the SOC from 48% to 44% initially?
It is making some assumptions? Or actually measuring this?

Interesting nonetheless.

After 19 days, my 12v battery was at 11.9v.
I noted the car charges at 14.5v for a while under these conditions, then the DC/DC converter was putting out 13.5v to 13.7v for the rest of the day.

Early on, ( early 2005 ) I heard of people frying cell phones, iPods, when using the 12v power point ( cigarette lighter ) plug, presumably because the voltage got too high. I've not heard of that in a long time, and I've never had issues. But the DC/DC output is variable.

 

I have been wondering about this also, as I have been troubleshooting my issue, I have notices this same behavior - the SG initially receives something close to where it was when turned off (and this appears to be actually received, not stored in the SG), then after a few seconds, it jumps to where the HVTB actually is, if you sit there for a while without starting the ICE, you will see the SOC continue to go down.

I am assuming that this is done thru a voltage measurement lookup based upon the results I am seeing, then after starting the ICE, the SOC is reported based upon counting ins and outs of the battery?

As an experiment, I disconnected the HVTB (Service disconnect, 6 pin HV and 40 pin Connectors) over night after having parked the truck with an SOC of 48%. 12 hours latter in the AM, I reconnected everything and started the feh - my SOC then reported 18% - so I am thinking I have a bad module somewhere within the HV battery that is slowly sipping off the stored juice - but for the purpose of your post, this is how I concluded it did a voltage lookup or something to calculate the initial SOC since it was totally disconnected and had no way to count / calculate anything in real time. But I don't know for sure, still somewhat of a guess?