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DIAGNOSTIC PROCEDURE FOR TH!NK NEIGHBOR TSB 05-4-12
ON-BOARD BATTERY CHARGER
THINK:
2002 Th!nk Neighbor
NOTE
ISSUE
FORD MOTOR COMPANY MAY REQUEST THE
Some TH!NK Neighbor electric vehicles may display
RETURN OF THE CAUSAL COMPONENT(S)
a low range, no start or a no charging condition.
LEADING TO BATTERY PACK REPLACEMENT.
This may be due to the on-board battery charger
WHEN BATTERIES ARE REPLACED UNDER
either overcharging, undercharging or not charging
WARRANTY, ALL RELATED CAUSAL
at all. These conditions may cause associated
COMPONENTS MUST BE HELD FOR 30 DAYS
damage to the battery pack, resulting in battery
FROM THE CLAIM SUBMISSION DATE. BE SURE
pack replacement.
TO INCLUDE BATTERY PACK AND INDIVIDUAL
ACTION
BATTERY VOLTAGES, ALONG WITH BATTERY
CHARGER OUTPUT VOLTAGE, IN COMMENTS
The following is an optional service procedure to
AREA OF THE REPAIR ORDER.
supplement the Workshop Manual procedure to
properly diagnose the function of the on-board
1. Remove the front seat stanchion and check
battery charger.
battery pack voltage by placing a DVOM
positive (+) probe onto the positive terminal of
SERVICE PROCEDURE
battery #6, and the DVOM negative (-) probe
WARNING
onto the negative terminal of battery #1 (Figure
THIS VEHICLE CONTAINS HIGH-VOLTAGE
1).
COMPONENTS AND WIRING. THE BATTERY
a. If the voltage reading is above 20V, proceed
PACK ASSEMBLY CAN DELIVER IN EXCESS OF
to Step 7.
72 VOLTS OF DC POWER. HIGH-VOLTAGE
INSULATED SAFETY GLOVES AND FACE
b. If voltage is below 20V, proceed to Step 2.
SHIELD MUST BE WORN WHEN PERFORMING
THIS TSB. FAILURE TO FOLLOW THIS
WARNING, OR IMPROPER HANDLING OF THE
BATTERY PACK MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH. ONLY
AUTHORIZED PERSONNEL TRAINED TO WORK
WITH HIGH-VOLTAGE AND BATTERY PACK
COMPONENTS ARE PERMITTED TO HANDLE
THE BATTERIES.
CAUTION
BEFORE WORKING ON THE BATTERY PACK,
THE SERVICE DISCONNECT SWITCH (SDS)
MUST BE TURNED OFF. THE SDS SHOULD
REMAIN OFF FOR THE DURATION OF THIS
PROCEDURE.
Figure 1 - Article 05-4-12
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation
determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin
(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is
available through Ford Motor Company’s on-line technical resources.
Copyright 2005 Ford Motor Company PAGE 1