Our 2006 FEH is having issues going from ICE to EV mode. It stutters, lurches a bit and the ABS light comes on? Anyone else have this issue??

We've taken it to the dealer and they couldn't replicate it in the road test. Today I road tested with the Service Mgr. and couldn't replicate it either. It comes and goes. Sometimes it happens and other times it's fine. Driving me a little nuts that I coouldn't replicate it with Service though.

 

Did they check for diagnostic trouble codes in the memory of the abs system?

 

They said they checked everything and nothing seemed strange.

 

This shudder, do you feel it in the brake pedal? Do you feel it on ICE start up at 10-20 mph? You might have warped rotors and only feeling them at the edge of regen braking. See if it will happen with more aggressive braking.

 

I can't tell you exactly when it happens because it is so inconsistent, I can brake hard or soft and it might happen. I should also mention that the ABS light flickers on then goes off right with the stutter/shudder. It feels like the ICE wants to keep going, like a delayed shut off going into the EV mode.

 

It also does not do it at start up, just going from ICE into EV mode after driving for awhile. I don't feel it in the brake pedal, just feels like the engine surging or still going after braking.

 

I wonder if your abs system is loosing power and resetting and going through a test which causes the brakes to pulse? Maybe a bad abs relay?

 

That's what I'm thinking, I know you said they didn't have a problem with it, but it's definately one, and one that sounds like it's going to be highly problematic. I'd have them check it again.

 

I think you guys have the right idea because it only happens when I brake, not when I coast into EV mode. I'm going to have them check again. Thanks for the insight.

 

I have seen MANY ford relays go intermittent and then fail, usually the contacts get corrosion on them from use/arching they will sometimes loose connection and then reconnect. Non hybrid brake systems are not active like ours and when ours reset they may be actuating momentarily.