The High Voltage System of a Mach-E GT
ฝัง
- เผยแพร่เมื่อ 7 ก.พ. 2025
- See the high voltage (HV) components of a 2021 Ford Mustang Mach E GT! Almost every electric vehicle has these same high voltage components. Learn their names and their basic functions.
I have been away from TH-cam for eight months developing a new training curriculum for my college classes and the hybrid and electric vehicle classes I offer to the public. I am back now and will be releasing new videos as quickly as I am able.
CORRECTIONS:
I was wrong about the hood electric open hood only, there is a release handle, but it is behind electrically opened doors. If the doors were locked when the 12V battery died, then a special procedure shown here is needed.
TIMELINE:
0:00 Start
0:08 Introduction
1:38 HV common component - The Front Motor Inverter
3:18 HV common component - The DC-to-DC Converter
4:45 The 12V AGM battery
5:28 MUST SEE: The under frunk Jump Start terminals
6:17 Remote auxiliary stud box to open the frunk if the 12V battery is dead
6:43 MUST SEE: The green colored under frunk Low Voltage Service Disconnect (LVSD) connector
7:28 MUST SEE: The low voltage low current and high current fuse blocks.
8:55 HV common component - The Electric Air-Conditioning Compressor
9:18 The coolant chiller
10:00 HV common component - The On-Board Charger Module
12:16 The two coolant expansion tanks (Reservoirs)
12:54 Passenger compartment heat and the four-way switching valve.
13:36 Why there are a few more coolant hoses than some other electric vehicles
14:23 HV common component - The Front Drive Unit and Motor
15:30 HV common component - The High Voltage Battery
16:18 The Electrical connections at the high voltage battery
16:26 The small orange connector receives up to 43 amps of DC current from the onboard charger when using an AC Level 1 or AC Level 2 plug-in charge cable.
16:26 The large orange connector receives up to 300 amps of DC current from a DC Fast Charge station when using a DC Level 2 plug-in charge cable.
17:25 The metal electrical connector feeds DC power to the front motor inverter
17:37 The black low voltage data and power connector
18:18 The coolant hose connections at the front of the battery
18:42 HV common component - The Cabin Coolant Heater
19:00 HV common component - The Rear Drive Unit and Motor
19:30 The coolant hose connections at the rear of the battery
20:00 Mercon ULV Drive Unit Fluid
20:28 Special adapters are required to lift the vehicle and remove the high voltage battery
24:00 Video Summary and EV Common Components
ABOUT US
Weber State University (WSU) - Davis Campus - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab. We teach current vehicle technologies to our automotive students at Weber State University and online. For more information visit: www.weber.edu/a...
This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see www.weber.edu/a...
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This is excellent!
Chiltons manual- $24.99
Motor all-data subscription- $199 per month
Weber auto on TH-cam- Priceless
Awesome, thanks for watching
Glad to have you back Kelly! I love recommending your videos to the newer techs we get in the shop, great content as always
Thank you very much!
Great to see you again Professor Kelly. Best regards from Vancouver Island.
Thank you very much!
Great to see you back Prof. Kelly! When I talk to anyone that wants hybrid/ev information I send them to your channel. I hope you get a Rivian R1T to show at some point. Thank you for all the videos you do.
Thanks Mike, I hope so too!
Happy to see you back Kellly!
Thank you so much!
This is such a important TH-cam Channel. The electrification of ground transportation is here and growing.
Thank you so much!
"I'm back." with an austrian accent should be the intro of the Prof. John "Explainiator" Kelly! 😎
Great to see you back, giving us starving crowds some brain food! 👍👍😁
Thank you very much!
Welcome back professor. Great to see a new video from you.
Thank you
THIS KING IS BACK!
LOL, thank you!
Hi Professor! I was starting to worry.
Glad to see you again!
Thank you! I am glad to be back
Glad to see you back uploading again. I really learn so much watching your videos. Thank you.
Thank you, I am glad you like them.
Glad to see you back!
Thank you very much!
Thank you Professor! It's great to see you and your latest video!
Thank you, more to come!
We miss you Mr Kelly nice to have you in the front, the stage is yours, and valuble information you always have ,thank you.
Thank you very much!
Glad to see you are back making videos.
I have to say that needing a battery to open the “frunk" in order to jump start the battery is the closest I have seen yet to a car manufacturer welding the hood shut.
I used to be really excited about electric cars, but the more I learn about them and the obstacles that manufacturers seem to put in the way of people being able to fix them on their own, the less I am inclined to want to get one anytime soon.
Thanks! I was wrong about electric open only, there is a release handle, but it is behind electrically opened doors. If the doors were locked when the 12V battery died, then the special procedure is needed.
I am glad Thatcher l coud hear and see your new video. Greetings from Poland.
Thank you!
Nice to see you back sensei, i was worried :c
Thank you!
You have been sorely missed. Great to see you back. And to think I thought electric vehicles could potentially simple!
Thank you very much
Glad to see you bud. I keep asking what happened to John. And I’m retired now. Still love to watch your videos though.
Thank you!
We are blessed to have you give such valuable time to us.
Thank you very much!
Welcome back, Professor! Thanks for a great video. Looking forward to the more in depth videos coming. Be well!
More to come! Thank you
Thankyou for sharing your wealth of knowledge
My pleasure
Good to see you again
Thank you very much
If I were surrounded by students, I'd be thinking about adding a locating pin or screw to the lift foot and adaptor block.
Thanks for taking the trouble to share the clear information that's hard to get anywhere else.
Thank you very much, That is a great idea.
Finally you are back. I was worried. Xmas is early this year.
Thank you!
Great to see you back! Would be great to hear something about the new Honda Civic Hybrid vs Honda CRV Hybrid. Both are ehev and probably are not sold in US.
I would like that. Thanks for the suggestion
So glad to see you are back and doing well. You surely have been busy. I have seen one report and photo of a Mach E that fell off a rack. I know you are diligent and safety conscious, stay safe. Hope to see your Honda Clarity battery some day 😀. Thank you so much for your efforts.
Oh wow! Yes, we lift the vehicle a few inches and then purposely try to rock is off the rack. I have a solid mounting for this video, but I can see where someone who is not paying attention could make a mistake, especially on older hoists with swing arms that do not lock.Thanks for the information.
Glad you are back making videos, Professor. Ford doesn't seem to have considered that the battery would need to be removed. Ouch.
Thank you!
nice to have you back Prof. Kelly
Thank you very much
Found your video on one of the Mach E owner forums, and bonus, you even covered my trim. Excellent work. great to learn more about my vehicle.
Thank you very much
I really wish i could take a course from you. The way you explain everything is very easy to understand and very clear. I been watching your videos for a while now and just wanted to say thanks for all the knowledge you share online.
I have no reason to be interested in this but great to see you back and am genuinely excited about what we have to learn coming up. Thank you.
Awesome, thank you!
Well we're happy to wait for your high quality videos. Looking forward to this series. You point out the hoses and their functionality, the Munro team likes to make fun of excess hoses!
Thank you very much!
I glad to see you again, and appreciate your efforts
Thank you so much!
glad to see you again sir!
More to come! Thank you.
Nice to see you back professor Kelly , thanks for sharing
My pleasure! Thank you
Welcome back to the world of the internet! Excited for some more Mach-e content.
Another item that most don't consider about jumpstarting any modern vehicle is that the jump points should ALWAYS be used. Besides the risk of sparks igniting any pooled hydrogen gas that you mentioned, anything recent uses a sensor to monitor power into and out of the battery. Charging or jumping the 12V battery at the terminals bypasses the sensor and will result in an incorrect learned charge state of the battery. Especially an issue with programming modules, which can take quite a while. The sensor just sees the battery being discharged, but not that a charger is connected, and will shut the ignition off and cause programming to fail. Common issue I've seen at dealers.
Thanks Jake, that is great information!
Thanks! Very glad to see you, and have to say again that the video is great, such a presentation is always good for knowledge and enjoyable too!
Thank you very much!
great to see you back, thanks for new series, I'll watch it, and I appreciate all work you're doing for popularizing engineering held under car manufacturing process
Thank you very much!
Great video as always, thanks for sharing it.
Thanks for watching!
Welcome back Professor Kelly!... always look forward for continuing educational videos.
Thank you kindly!
Prof, we missed your juicy contents. Welcome back.
Thank you very much!
Welcome back! Mach-e has been a fun one so far, the recall is something ford has been doing lately as in updating software in hopes to prevent a hardware failure but the failure can still occur. If the contactors stick it’s usually the dc fast charge contactors are welding from the heat and so far I’ve seen all happen at electrify America stations. To repair the battery has to come out and high voltage battery junction box has to be replaced.
Thank you, you are correct. The battery has to come out to replace the contactors
Awesome! I can't wait to see more of this vehicle. Your video on the Volt battery was extremely helpful in disassembling my own. Much appreciated.
Great to hear! Thank you
Welcome back sir 🍻
Thank you John
Díky!
Thank you very much!
Really great to see you back, Professor Kelly. Your videos are always excellent regardless of the topic at hand.
Thank you very much!
Thank you for your insights.
As always the knowledge you share is a gold mine.
I can't wait the next steps.
Thanks for watching!
Great to see you back Professor Kelly
Thank you very much!
Thank you.
You are welcome, thanks for watching.
Welcome back Professor John Kelly.
Thank you!
Welcome back, Professor! Thanks for a great video is Very informative 👍👍👍
Thank you very much!
Nice, looking forward to more on this Mustang!
Coming soon!
Heyyy professor .... un gusto verlo bien. Saludos desde republica dominicana!!!
Thank you!
You were really missed and I am glad we will be educated on car design.
Thank you!
Very informative video again! We are waiting for your next future videos of this car. Good luck
Coming soon! thank you
Nice to see your still there, I look forward to your tutorials, 👍👍👍
And iam not even a mech, iam a air-conditioning/ refrigeration engineer
Thank you very much
I like see you again Mr Kelly and thanks for share this video
You are so welcome
Thank you professor. I always enjoy your videos.
You are very welcome
Welcome back professor so great to see you 👋😎👋😎
Thank you kindly
Happy to see you again🤗🤗🤗🤗
Thank you so much 😀
I'm glad you're ok. Busy is good. Thanks for the video
My pleasure. Thank you!
Terima kasih Prof Kelly. Amat menarik video EV yang disampaikan kepada semua
terima kasih banyak-banyak
Great to see your well👍
Thanks 👍
Good day. Thank you for a great dose of interesting knowledge about electric drives. Best regards.
Thanks for watching!
Thank you for these interesting and informative videos Professor Kelly. The technology and engineering used on these EV's is quite impressive. It's a fusion of electrical and mechanical technology applied to transportation. The series on both the Tesla vehicles and this Mach E GT have been especially interesting and a good primer for anyone wanting to understand the underlying technology that make electric vehicles possible and practical.
17:38 the grey metallic connector is for DC to the inverter? For the front motor?
I’m surprised it isn’t orange. It also doesn’t look big enough for the front inverter u less that front motor isn’t that powerful and I just over estimated the size needed.
Welcome back, Professor. It’s always a pleasure to hear your voice and see your work.
It is for the front inverter. Only the cables are required to be orange, not connectors. Thank you!
Wellcom back professor, what a great video 👍🏻
Thank you kindly!
Many thanks, another great video! Please do keep them coming as they are very interesting & your delivery is always entertaining. Any chance of an ID4 strip down please?
Thank you. I hope so
Truly enjoyed the EV bootcamp a couple of weeks back! Thanks for everything you do!
Glad you enjoyed it! Thanks for attending!
Great video, thanks for for posting.
I Got a good laugh at a high end electric car has a AGM 12 volt battery under the hood, even my Ioniq doesn't have a separate battery anymore. The BMS does a good job keeping the battery from draining till is not useable.
The Ionic is unique, all the other ones I have seen still use a 12V battery. Thanks for sharing!
@@WeberAuto Learn something new everyday
Cant' wait to see those contactors opened inside 👋😎👋😎💥💥💥💥💥
You and me both!
It's always a pleasure!
Thank you!
Another fabulous video!! I really enjoy all of what you do!! Would it be possible to support the vehicle by the wheels when removing the battery?
Thank you very much! I suspect it is possible if you had that type of lift, but would there be room to safely lower the battery and move it out from under the car? The adapters I use in the video are official the Ford service tools for battery service on the Mach-E.
Wooot! The Professor is back!!!
Thank you!
Nice to have you back. The fill and drain plugs on the electric motors are for the lubricating oil aren't they? Not for the coolant?
Thank you, yes, they are for the Mercon ULV transmission fluid. I did not mean to say coolant drain and fill plugs. Good catch!
New video, cooool ⚡
🤜🤛
Thank you!
I see a new Weber Auto video, I click. I totally understand taking some time away from TH-cam to do your work, but I’m glad to see a new video. Even though I no longer work as a tech (and I’ve had quite a bit of training on hybrids and BEVs in the past) I’m still really tempted to find time to come to the 5 day boot camp.
It’s interesting that Ford chose to put an insulating wrap on the front drive motor. Do you believe that is for noise insulation or trying to insulate the front motor from under hood heat? I know the AC and battery cooling can cause a lot of heat under the hood, and I’ve actually seen the effects of this heat in the transmission fluid (motor) temperature sensors on my Bolt (I’m sure it’s even worse on my Ioniq5 but I haven’t seen fluid temperatures on it)
Awesome, thank you!
I totally recomme d the boot camp
Tank you. This was great info. I actually have two Mach-Es. Both awdxr and both premiums.
Thank you very much
Great Info John.. Thanks for these very informative videos.
Hi John Lovely to hear from you again, you have been missed !
Glad that everything is all right.
The heating loop is a clever thing that many other can learn from.
Regarding charting, level one and two. Many people call them charter however it is only Communication port and a Power contactor.
This is often misunderstood especially when we talk prices.
How do I get hold of the charging communication, I am especially interested in state of chart and the amount of amps going into the battery.
Lovely video from you again, nice to have you back 👍
Thank you very much. Yes, you are correct, the terminology is confusing for many people. I call it a charger cord, not a charger. See the SAE J1772 standard for that information.
Thank you!
You are welcome, thanks for watching
Good you came back professional
Thank you!
After long time mr.kelly!!
Yes, a long time
Do all electric cars have 2 coolant expansion tanks or is it specific to the mach e? From the videos of electric cars I have seen they all have 1 coolant tank unless there is a second one hidden
Good question! Here is the long answer. Almost all electric cars have the same common high voltage components shown in this video. Most of those components need to be cooled or heated. The cooling or heating of those components involves using many coolant hoses, pumps, switching valves, radiators, chillers, etc.
The parts used for the high voltage battery cooling and heating are typically isolated from the other high voltage components in an isolated coolant loop. The remaining high voltage components also have an isolated coolant loop. Some cars have a switching valve that can place the two coolant loops in series or parallel as needed.
Some electric cars use a separate expansion tank for each isolated coolant loop, while others use a single expansion tank that feeds both coolant loops.
Later model Tesla vehicles are using a clever expansion tank design that attaches some of the pumps, switching valves, and a chiller to the tank housing, thereby eliminating the need for some coolant hoses.
Brilliant stuff . Very interesting indeed thanks a lot
Do an f150 hybrid and lightning! It would be very interesting to compare the two cars and how their architecture and design compare
Thank you, I suspect they have many similarities.
I'd find a way to augment those lift brackets. Either by adding an extension or an adapter on the lift that interfaces better. Relying on the lift arm lock to keep that pad under there is not the smartest idea.
Thanks for the suggestions, I am working on finding a more secure method.
Wonder if the remote column style lifts are safer for battery removal . Or is the weight stress on center of car to great
I do not know. Thanks for watching
That lifting situation does seem a little sketchy. I think I would either have some stationary supports at the suspension like the Munro guys sometimes use, or column lifts like Leno's shop has, if I were removing battery packs on a regular basis.
Agreed, but the challenge is being able to lower the battery and move it out from under the car without interference from the vehicle lifting system being used. Finding proper vehicle lift points for stationary supports without damaging the vehicle is also a challenge. Unlike the Munro guys, these vehicles need to function again when the work is completed. Thanks for your feedback.
Very informative video Mr. Kelly! I'm curious, did Ford label things with the yellow stickers or did you guys go through & do that? Very convenient if Ford did it:-)
Thanky you, it was me. I am well known for my yellow labels. There is even one on the thumbnail for this video ;)
@@WeberAuto The modern thermal labels/makers sure beat the old embossed labels😀
Hi John great content and your courses are the best out there . I have a question about the silver plug on the high voltage battery . I thought all high voltage wires and plugs are orange that was industry normal and i think it is required . Can you explain why on this car the high voltage plug is silver. Thank you.
Thanks Dan! Yes, U.S. Federal Motor Vehicle Safety Standard (FMVSS) 305 states "Cables for high voltage sources which are not located within electrical protection barriers shall be identified by having an outer covering with the color orange."
Cables are required to be orange, but not the connectors. Most high voltage connectors are orange, but there are many I have seen that are not.
Thanks John with all the connectors I have seen are orange but thank you for the clarification.
Are the high current contractors in a V configuration. So they wipe slightly and are less likely to weld shut . Or does the solenoid have a high lead screw pitch to rotate the contact discs with every close command?
Good question, I do not know the answer yet.
I'd have safety stands under the car, given those sketchy lift blocks. It looks like the lift pads' pins are being side loaded instead of vertically loaded by the pads....just a matter of time for the pins to fatigue & fail with being load cycled each time the Mach-E is lifted, imo.
Thanks, good idea!
Good video. Why do we need heater for the battery?
Thanks.
For maximum battery efficiency it needs to stay within a certain temperature range.
@@WeberAuto Thanks for your excellent work. Keep it up.
Ford must have a manual override cable to open thr frok, maybe it's inside the drivers side?
Yes, I was wrong. There is an inside hood release, but it is behind an electrically opened car door. ;)
Is it still 50/50 ethylene glycol antifreeze and water mixture for the cooling system?
15:45 I suggest not to wear any rings on fingers while working on cars and/or electronics for security reasons.
Good suggestion
Is the 12v battery iron phosphate or other lithium type?
I would make up some custom lift mount points to suit the adapters, better to be safe than sorry, wouldn't be a huge job.
The 12V battery is an AGM lead acid battery
Will these vehicles be compatible with OBD2 comms? I took a Tesla class and having the equipment to communicate and diagnose those vehicles is difficult due to so much proprietary equipment. Being that it's a Ford I wonder if we'll be able to use a normal obd2 port and look at live data etc.
There is a normal DLC on this car, so yes for some PIDS, but since these cars are emissions free, they are not required to comply with OBD regulations. However, My Snap-On Apollo D9 scan tool works great with this car and the Explorer hybrid.