Charge door ajar warning but not open?

[MCT]

Started up a few days ago and received a few warnings. I’ve got the powertrain malfunction warning and also charge door open warning. This continues three days later. Functionally, the truck is still running perfect, no reduced power and charge door is closed when it thinks it’s open. Anyone have any experience with this? I’ve made an appointment at the dealer later this week. I’m less than 1000km out of warranty….

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[RickLightning]

I don't know if the charger door warning is tied to the hinge, or tied to the physical latch, but I'd look into both before headed to the dealership. I would consider blowing out each with compressed air, then spraying both with silicone spray as a first step.

 

[RLXXI]

On the 25 it's unclear what triggers that warning except to say it looks like it may be part of the handle release button/charge indicator as that's the only wiring shown leading up to the charge port assembly.

YMMV.

 

[chriserx]

On the 25 it's unclear what triggers that warning except to say it looks like it may be part of the handle release button/charge indicator as that's the only wiring shown leading up to the charge port assembly.

YMMV.

So after looking at that pic and watching state of charge's door replacement I suspected there was a hall effect or similar type sensor. Went outside with a neodymium magnet. Sure enough if you hover over the unlock button with the magnet, the lighted ring turns off, wave hand stays on, move magnet to the door, depending on poles, it repels or attracts at.... fk it went back outside and took some quick pics, apologize for quality issues, was too bright to see the screen...

So diagnostically, get a strong magnet, hover over the charge light, if it cuts off, the sensor is fine (which means its not a proximity or PV type sensor), if not you'll likely have to replace the assembly. Next place magnet over the door in the pic, if it doesn't attract/repel its missing, replace it. If it does attract/repel its likely demagnetized, replace it. Good luck!

 

[MCT]

Thanks for your help with diagnosing. I tried the magnet idea. It didn’t seem to affect the charge light. When I open the charge door, the blue light pulses like it’s charging, but there is no charge cable attached. The blue light goes off after about 5 seconds. I plug in the charge cable and no light goes on at all, but the truck begins charging. I did watch the state of charge video on charge door asm replacement. I think there might be moisture damage in the connections but since the temperature here is just above freezing I’m not sure that cold plastic won’t snap when I try to disassemble it.

 

[chriserx]

Thanks for your help with diagnosing. I tried the magnet idea. It didn’t seem to affect the charge light. When I open the charge door, the blue light pulses like it’s charging, but there is no charge cable attached. The blue light goes off after about 5 seconds. I plug in the charge cable and no light goes on at all, but the truck begins charging. I did watch the state of charge video on charge door asm replacement. I think there might be moisture damage in the connections but since the temperature here is just above freezing I’m not sure that cold plastic won’t snap when I try to disassemble it.

I just went outside to test it while charging but I can't since I'm at 100% . Test it while not charging, and make sure that you are using a strong enough magnet, most fridge magnets likely won't cut the cake.

Edit: Ohhhh I misread it, try a 12v reset. Just unhook the battery for a couple minutes.

 

[MCT]

My next option, as you mention, is a 12v reset. Maybe will try later in the week after the weather warms up a bit. Functionally, the truck operates perfectly, it just the charge light and dash warning of charge door open and powertrain malfunction that is the issue. I’ve got two outstanding recalls that I need to bring it in for anyway so if I can’t solve it by Wednesday, Ford will have a look at it on Thursday.

 

[Maquis]

The charge port is covered by the 8/100K EV component warranty.

 

[Adventureboy]

the blue light pulses like it’s charging, but there is no charge cable attached. The blue light goes off after about 5 seconds.

This is abnormal behaviour. I have not seen the blue lights unless an EVSE or DCFC is attached. Plusing means it thinks it is charging.

Perhaps try this process first.
https://www.f150lightningforum.com/...rging-error-on-dcfc-post-5.35390/#post-656249

 

[chl]

Since you have multiple error/malfunction warnings, that is sometimes a sign of a weak 12v battery - when weak it sheds loads and then diagnostic tests fail and warnings are issued.

The charge port door ajar sensing may be one of the systems that gets off-loaded when the battery is weak. Could be related to the charge ring issue as well.

There has/have been quite a variety of weird errors when the 12v battery begins to fail, so see if that is the issue.

In cold weather (which you mentioned) battery chemistry slows down and weak batteries can export even less energy than when they are warm.

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