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2.7L Dies While Driving. Diagnoses: battery junction box failure

amcdermond

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Well, it looks like the honeymoon is over. I have a 2022 Wildtrak (2.7 HOSS 3.0). While I was driving to a medical appointment in the next town over, it started bucking while I was driving it. It took me a bit to figure out that the engine was actually dying and restarting quickly while driving. I got it pulled over to a safe spot in the road and turned it off. When I tried to restart the car, it’d turn the starter, and fire, but run very roughly for about ten seconds before dying again. When I opened the hood, I didn’t see anything immediately wrong, but I could hear a relay buzzing, which didn’t seem normal to me.

I used the FordPass app to summon roadside assistance. When they assigned a tow company it was one that was two towns over and 20 miles from where I was on the side of the road (in the Mid-Willamette Valley in Oregon). It took them over an hour to get to me. Meanwhile I was inside the city limits of a town 5x the side of where the towing company was, and I know has many towing alternatives. If this wasn’t bad enough, the status updates were horrendous. The maps sent to me via text message were worthless as they never showed the tow truck moving at all. The map on the FordPass app never even showed a tow truck on it ever. Their automated system would tell me that the tow truck was 40 minutes away every 10 minutes. Meanwhile the temperature is dropping and I’m stuck in a car with no heat. I was on the verge of calling my State Farm roadside assistance instead when the tow truck finally showed up. Honestly, I’d rather have *no* service than *bad* service from Ford for this.

I got it towed to the local Ford dealer. Unfortunately not the one I purchased it from. They are saying that the “battery junction box” is bad and that they’ve ordered a new one for replacement. I’m assuming this is the fuse box in the engine bay in the Bronco. I’m kinda confused at how this can even go bad. I recently installed a ham radia in the car (Yaesu FTM-400XDR) and hooked wiring to the provided terminals on the battery. The power was fused on both sides 4” from the battery connections, so any shorts in it should have blown those pretty quickly. I’m pretty afraid that the dealer/Ford will try to pass off the bad fuse box as a consequence of my radio installation. I’ve been a ham for like 35 years now, and I know how to do a safe radio installation.

I’m pretty disappointed at this point. I’ve had this car for less than a month and it has all of 1200 miles on it. I am much more tolerant of a trim piece that’s not quite right or a software bug in the infotainment system than I am an engine that cuts out on the road while driving. I haven’t been left by the side of the road by a car since I was in my 20’s and driving 20 year old cars with hundreds of thousands of miles on them. I’ve bought four cars new, three Hondas and an Audi, and have never been stranded by any of them. I understand infant mortality and such, but it still makes me question my decision and makes me nervous about even attempting any of the snow wheeling that I was intending to try out this winter.

The dealership is saying that the new part will take five days to arrive, and then they’ll see when they can put it on. I guess I’m spoiled by Amazon these days and expect it’d take a lot shorter time than that to get a part in. So, as of next when when I potentially get it, my car will have been out of service for 20% of the time I have owned it.

I’ll try to post a follow-up with some resolution when I hear back next week. As far as learning experiences, if you have AAA or another roadside assistance service available to you, I’d suggest calling them before Ford’s. Thanks for letting me vent about things. :)
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Jeff Lebowski

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Bummer man. Sorry to hear….Did you notice any voltage fluctuations from the display gauges ?
 

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Well, it looks like the honeymoon is over. I have a 2022 Wildtrak (2.7 HOSS 3.0). While I was driving to a medical appointment in the next town over, it started bucking while I was driving it. It took me a bit to figure out that the engine was actually dying and restarting quickly while driving. I got it pulled over to a safe spot in the road and turned it off. When I tried to restart the car, it’d turn the starter, and fire, but run very roughly for about ten seconds before dying again. When I opened the hood, I didn’t see anything immediately wrong, but I could hear a relay buzzing, which didn’t seem normal to me.

I used the FordPass app to summon roadside assistance. When they assigned a tow company it was one that was two towns over and 20 miles from where I was on the side of the road (in the Mid-Willamette Valley in Oregon). It took them over an hour to get to me. Meanwhile I was inside the city limits of a town 5x the side of where the towing company was, and I know has many towing alternatives. If this wasn’t bad enough, the status updates were horrendous. The maps sent to me via text message were worthless as they never showed the tow truck moving at all. The map on the FordPass app never even showed a tow truck on it ever. Their automated system would tell me that the tow truck was 40 minutes away every 10 minutes. Meanwhile the temperature is dropping and I’m stuck in a car with no heat. I was on the verge of calling my State Farm roadside assistance instead when the tow truck finally showed up. Honestly, I’d rather have *no* service than *bad* service from Ford for this.

I got it towed to the local Ford dealer. Unfortunately not the one I purchased it from. They are saying that the “battery junction box” is bad and that they’ve ordered a new one for replacement. I’m assuming this is the fuse box in the engine bay in the Bronco. I’m kinda confused at how this can even go bad. I recently installed a ham radia in the car (Yaesu FTM-400XDR) and hooked wiring to the provided terminals on the battery. The power was fused on both sides 4” from the battery connections, so any shorts in it should have blown those pretty quickly. I’m pretty afraid that the dealer/Ford will try to pass off the bad fuse box as a consequence of my radio installation. I’ve been a ham for like 35 years now, and I know how to do a safe radio installation.

I’m pretty disappointed at this point. I’ve had this car for less than a month and it has all of 1200 miles on it. I am much more tolerant of a trim piece that’s not quite right or a software bug in the infotainment system than I am an engine that cuts out on the road while driving. I haven’t been left by the side of the road by a car since I was in my 20’s and driving 20 year old cars with hundreds of thousands of miles on them. I’ve bought four cars new, three Hondas and an Audi, and have never been stranded by any of them. I understand infant mortality and such, but it still makes me question my decision and makes me nervous about even attempting any of the snow wheeling that I was intending to try out this winter.

The dealership is saying that the new part will take five days to arrive, and then they’ll see when they can put it on. I guess I’m spoiled by Amazon these days and expect it’d take a lot shorter time than that to get a part in. So, as of next when when I potentially get it, my car will have been out of service for 20% of the time I have owned it.

I’ll try to post a follow-up with some resolution when I hear back next week. As far as learning experiences, if you have AAA or another roadside assistance service available to you, I’d suggest calling them before Ford’s. Thanks for letting me vent about things. :)
Sorry to hear OP, I agree there’s a big difference between a car that spends a lot of time in the shop vs. leaving you for dead. I’ve driven mostly German cars before Ford and I’m no stranger to a CEL or repair bill. But I’ve never once been left stranded either!
 

Havanajoe

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Sorry for your troubles im waiting for this to happen to me since it’s all over this forum and once it does im selling the bronco I’ll never trust it again like you I’ve owned everything under the sun and NEVER BEEN LEFT ON THE SIDE OF THE ROAD ITS UNACEPTABLE now days. I’m afraid to venture too far from my home to go wheeling what if I get stranded off-road? Good luck keep us up to date.
 

JediMcMuffin

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Sorry for your troubles im waiting for this to happen to me since it’s all over this forum and once it does im selling the bronco I’ll never trust it again like you I’ve owned everything under the sun and NEVER BEEN LEFT ON THE SIDE OF THE ROAD ITS UNACEPTABLE now days. I’m afraid to venture too far from my home to go wheeling what if I get stranded off-road? Good luck keep us up to date.
You better have a plan for that what if I get stranded off-road question regardless of what you’re driving or how reliable it is. Shit happens. What if the guy in front of you has a brake failure and rolls backward and punctures your radiator?

I was worried for a long time about the 2.7L valve failure but it’s not even a thought now. Ford quality control isn’t exactly a new problem. Then again I’ve see a shitload of broken Chrysler products too, oh and Volkswagens and even the occasional Honda.
 

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Sorry for your troubles im waiting for this to happen to me since it’s all over this forum and once it does im selling the bronco I’ll never trust it again like you I’ve owned everything under the sun and NEVER BEEN LEFT ON THE SIDE OF THE ROAD ITS UNACEPTABLE now days. I’m afraid to venture too far from my home to go wheeling what if I get stranded off-road?
Lol, if you are that afraid and paranoid then you should probably just sell it. Why hang on to a vehicle that is obviously bringing you no joy? 19k combined on my 2, no issues and no worries.

OP, it kinda sounds like the Bronco was starving for fuel. I wonder if it was the fuel pump problem that has popped up on a few Broncos? Since they stated it was electrical, were you able to check you fuses and grounds to see if they were secure. Loose electrical bits tend to cause all sorts of phantom problems. Also, any chance you can get it moved to your preferred dealer?
 

Havanajoe

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I’m not saying I won’t use it but the first time it leaves me stranded it’s gone. Off-road? I’m talking about a failure with the bronco not other conditions.
I am enjoying it but it’s always in The back of my mind.
 

JediMcMuffin

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I’m not saying I won’t use it but the first time it leaves me stranded it’s gone. Off-road? I’m talking about a failure with the bronco not other conditions.
I am enjoying it but it’s always in The back of my mind.
Might want to put in an order with Toyota now then :D
 

rtazz17

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in all honesty you are more likely to be stranded now then in older vehicles since the new vehicles will put you in limp mode for whatever reason,sensor etc. Older vehicles you would get home to fix it. Having said that,you need to find out what caused it for sure. Not saying its your fault but we all make mistakes in our garages no matter how experienced we are installing things. Especially anything to do with wiring. Good luck.
 
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amcdermond

amcdermond

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Bummer man. Sorry to hear….Did you notice any voltage fluctuations from the display gauges ?
I didn't notice anything on any gauges. I didn't have any of the voltage gauges up. That being said, I saw no warnings on the screen at all and the FordPass app doesn't say anything is wrong with it. I would expect that if there were big time voltage fluctuations it'd be throwing warnings all over the place for bunches of different systems. Additionally, I'm pretty sure my ham radio would respond poorly to a bunch of brownouts and that just didn't happen.


You better have a plan for that what if I get stranded off-road question regardless of what you’re driving or how reliable it is. Shit happens. What if the guy in front of you has a brake failure and rolls backward and punctures your radiator?
I get it. I'm being a bit of a drama queen. I'm pretty new to off-roading in general. I've been down a bunch of USFS roads on both four and two wheels in my life, but never much off of that. I have been looking forward to a vehicle that can take me more places. Your comment on having a plan is really well taken. I really need to find a group locally to go out with.

I certainly am not planning on getting rid of it at this point in time. It's great when it has run, and the Bronco name has a lot of nostalgia for me. My grandfather had an EB in the 1970s when I was a little kid. Whenever we'd go out and do something fun like take the boat to the lake or drag the snowmobiles up to the mountains, we'd be taking "Mr. Bronco" to do it. Part of my Bronco ownership is honoring his memory.

OP, it kinda sounds like the Bronco was starving for fuel. I wonder if it was the fuel pump problem that has popped up on a few Broncos? Since they stated it was electrical, were you able to check you fuses and grounds to see if they were secure. Loose electrical bits tend to cause all sorts of phantom problems. Also, any chance you can get it moved to your preferred dealer?
I am too wondering whether it's a fuel pump issue. That would better explain what I saw. Although it could be the fuse connection to the fuel pump or something dumb like that too. The service guy said something about checking for voltage on the far side of the "battery junction box" and not seeing any. I don't really think that matches what I saw.

I did check over the ground connection on the battery really quickly to make sure it looked good, and didn't find anything. I didn't check any of the fuses at the time; it was getting pretty dark and cold by that point.

It's not really practicable to get it moved to the dealer I bought it from. They're like 40-50 miles away from where the car is and about the same from where I live. I reserved at the start of January 2021 and figured that the dealer in Eugene was probably going to get more allocation than one in Corvallis or Albany. With all respect to the folks that are still waiting for theirs after reserving months before me, it was probably a fortuitous decision. That dealer apparently had the first stand-alone Bronco dealership in the country, so I'm assuming their allocation was pretty good. The downside of that decision is that they are not exactly "convenient" or the closest dealer to me. They're about an hour drive away.
 

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What a bummer. I just got my BD last week and am 50 miles in. I love the ride but.....I too have this worry at the back of my mind as mine is a 2.7L as well. Good luck and I hope you are able to get to the root cause of your issue! I just signed up for AAA Premier plan earlier today. Lol!!!
 

Raptor911

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you guys worry too much. If something fails then warranty will cover it.

My wife's wildtrak has 8000+ miles and she absolutely loves it.

What a bummer. I just got my BD last week and am 50 miles in. I love the ride but.....I too have this worry at the back of my mind as mine is a 2.7L as well. Good luck and I hope you are able to get to the root cause of your issue! I just signed up for AAA Premier plan earlier today. Lol!!!
 

Billnchristy

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We all have to remember that issues are going to be the first thing talked about. Sure there are a lot of "I love my Bronco" posts, but a lot of folks only come on forums when there are problems (not saying that's you OP) and it gets real easy to get worried. It's all a probability game and with the parts shortages and supply issues, it's been amplified. Maybe stuff that wouldn't pass in the past does now because otherwise it's another month wait...who knows. We're all early adopters and we're making life easier for the next guy.
 

miami2823

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you guys worry too much. If something fails then warranty will cover it.

My wife's wildtrak has 8000+ miles and she absolutely loves it.
Idk, it seems from what people are posting on this website that Ford warranty coverage is becoming more and more of a meme at this point.
 

Raptor911

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and worrying about it makes it better?

Again enjoy you Bronco. If you are unable to then buy something else that you will enjoy.

Idk, it seems from what people are posting on this website that Ford warranty coverage is becoming more and more of a meme at this point.
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