41% SoC is on the low side. It shouldn't generally be that low after 20 minutes of driving unless you were being very aggressive with EV mode.

 

2 tricks I would suggest:
1) put transmission in 'L' and drive around for a while, watch your scanner to see how the regen/assist is going. It's ok to run around in L all the time, I've been doing it for over 150,000 miles and the only time I go in to 'D' is when I'm going down a long downhill and need to use regular brakes.
2) Park in an empty lot or other flat open space with the engine running, wait for it to top off the HV battery, then see how long you can run around in EV mode at low speeds (<20 mph). It should be able to run for at least a few mins without the ICE kicking in.

 

The SOC should be around 53% after driving for 20 minutes. In fact it should get there within 5 minutes of driving, depending on outside temperatures and what the SOC was when you started the vehicle. I suspect that you're encountering some form of HV battery charging issue. The cold weather will definitely mess with your SOC at startup, especially if you drained some power off (drove in EV mode) for the last mile or two before shutdown the previous night. There's something wrong if you're driving around with SOC readings that low after initial warm up.

My FEH (2005 w/230K+) will reach full SOC at 53% within 5 minutes, regardless of how low it was when I started out. It really doesn't like a cold day and SOC below 20% to start out. It will behave strangely if these parameters exist. High revving, hesitation and generally complaining about getting moving like a teenager being dragged out of bed. These symptoms all subside after about a minute and it will still reach full operating SOC within 5 minutes.

Keep in mind that an HV battery charging issue doesn't automatically mean that your battery is somehow failing. There are other factors that can interfere with HV battery charging such as battery cooling fan failure, corrosion on connectors or corrosion on the computer connectors. I suggest finding a hybrid specialist in your area to have them do a system check. Or maybe just describe what's happening and get their opinion as to whether or not it may be a charging issue.

I live in the Seattle area and we have a shop here who does HV refurbishing. These guys are experts and they often know more about these vehicles than the factory techs do.

 

Hi there everyone.

Didn't want to bump an old thread but I figured I would provide an update.

As it turns out, the catalytic converter on my 05 FEH was clogged. When I figured this out, the damage was already done.

Back pressure caused by the catalytic converter ruined the engine, I now have a very audible rod knock.

I've decided that I'm going to buy an engine here in Los Angeles, CA and replace the engine myself in my garage despite the fact that I've never done such a thing.

Salvage yard here in Los Angeles, CA area has a 06 FEH long block engine with 78k miles. Employee said its been compression tested and was working fine until the vehicle was a in rear collision. Said he doesn't have the VIN number. I'm not entirely sure what to look for when getting a used engine besides the visual stuff like no cracks or leaks on the body itself and no dents in the oil pan.

Here are some pictures of the engine itself at the salvage yard: https://imgur.com/a/g6Umb2f

Questions for you guys:

1) Based on the pictures, does the engine look like its in good condition?

2) Besides the gaskets on intake/exhaust manifold, what else should be changed or replaced? I'm thinking serpentine belt, electronic throttle body gasket, anything else?

3) Can I put an 06 FEH engine into an 05 FEH?

Thanks everyone, I know I'm in a little over my head as I have never done this but with the help of some good friends and the fact that I love this car, I think its possible for me to restore this car into good working order again.

 

 

I'm not sure that lucky is the operative word in my scenario. Nor would I call them MY trusted shop/mechanic but I see where you're coming from.

This has been a rather pain enduring and difficult journey having to deal with mechanics who have no idea what the problem is, or don't understand how to correctly diagnose the issue. Really seems to me that Ford hires incompetent mechanics here in the Los Angeles area. Had another mechanic put red coolant into my FEH that clearly doesn't take that color.