It seems to be the thermostat the one we replaced wouldnt open either. The ac is working fine, but i have noticed that when i run it, the stop safely now comes on much sooner.

 

Luckily I haven't gotten the dreaded "Stop safely Now" in the 1 1/2 years I've owned my '05 FEH. I kinda assume the MECS pump had been replaced before I got the vehicle (w/113K miles).
I was wondering if anyone knows what temp (scangauge - MECS temp) would trigger this "Stop Safely Now" message?

 

Here I am to resurrect this thread one more time. Last night this happened to me twice on the highway -- each time I pulled over to the side of the road, waited a minute or two, and restarted.

It started happening after I got $20 of gas from a really crappy gas station out of nowhere. I only got $20 rather than a fill-up because they had a total rip-off price. I think my problem is bad fuel but I won't be able to get it to the dealer until tomorrow. If I have anything to add I'll post it.

 

amazingly my problem was also fuel related, being in a third world country i would usually purchase my fuel in mexico and transport it into belize. in doing so i was storing it in metal drums. the fuel did go thru a 2 micron filter before going back into my vehicle. ive had this vehicle for 2 and a half years and sudennly i had 2 months of non stop problems. sorry getting chatty long story short what was causing my stop saely now was my fuel system was filthy had to clean injectors, change filter, clean out fuel tank and clear about 1/8 of an inch of crud or sludge off both filters on the fuel pump and the vehicle is running like a champ again.

 

OK here's my story: the dealership had no trouble finding out what was wrong from the sensor logs. The Hybrid battery cooling system -- both fan and fluid pump -- had failed. The system was going into "preservation mode" in order to avoid damage to the battery pack.

Cost to repair: $1800. After discounts and stuff: $1400. Sucks.

If the Tesla Model X was available I would go test drive one now.

 

Sorry about the problems. Hard to figure out how this could have been triggered by poor gasoline quality. Could just be a coincidence though. Anyway, the pump replacement is pretty easy and would only cost you parts and a jug of coolant. Maybe around $160 plus 2 hrs of your time. The replacement procedure is well documented in this thread. I did mine a few months ago and it was pretty easy. I don't know anything about the fan. Maybe other forum members can chime in on that. Hopefully at least the the pump can save you some money. Good luck!

 

How many miles on the vehicle? The HVTB cooling fans are covered by the separate hybrid component warranty. 8 years/100,000 miles or 10 years/150,000 miles in the "green" states.

 

Really? I have only 80K miles. I'm going to go pick up the car in an hour and I'll ask them about it. Thanks.

 

There is no fluid pump for the battery cooling unless you consider the compressor the "pump."

 

There is a Motor Electronics Cooling System (MECS) pump that does go out on the FEH. (it's like a mini radiator and pump for these electronics.) As 'deprotinator' said, easily replaceable by a handy DIY mechanic type.
Also I replaced the HVTB cooling fans myself last fall for the cost of parts (little over $200) and about a hour of my time. There are instructions w/pictures available for this repair here-> http://forums.edmunds.com/discussion...k-questions/p3