Pre-fuse box/Battery mounted fuse link, 225A fuse, charging system service now

[FordCurious2124]

Hi everyone!

I've had a confusing situation come up and I want to understand what happened and how, whether I got hosed on the repair, and anything I should do to prevent it happening again in the future.

I have a 2021 Ford Ranger.

A couple of months ago, I got the alarm bell and the red "Charging System Service Now" indicator light. Pretty terrifying to find out that meant my truck should shut off any time while driving. I live in a mountainous area and that could be life threatening to me and others.

I brought it to my local Ford dealership two times and they couldn't figure out what the problem was. I brought it to O'Reilly Auto Parts and they scanned the battery and alternator and said they were both fine. The indicator light started coming on more and more frequently.

I made an appointment with another Ford dealership in the "big city" near me. They identified that the 225A fuse had broken, and said they had to change out the entire pre-fuse box. The cost for the part was $200 and with labor and "shop supplies" came out to $578. I just want to see if I got hosed for what maybe should have been just replacing a fuse that cost $12. It seems to be that if the entire pre-fuse box was replaced, this also neccesitated re-programming.

I also want to know why it happened. Perusing this forum and others, it seems that it could be the auto start-stop, maybe its the auxiliary lightbar I put on, and also, when I bought the car, the prior owner had put an after market blow-off valve on it. I'm sure there are many options, but I've also seen that the 225A fuse would need some sort of serious blow to pop. So I am wondering what you all think.

I am also very, very, nervous because, as you all likely know, people talk mad sh*t on Fords. This is my first one. I've previously had Subarus and Hondas and even when they were old beaters, I never had to do any repairs. For a '21 truck with 66k miles on it, I don't know if this type of issue is normal, or if I should be more worried that my truck has started its downfall and maybe I should try to sell it. I have otherwise loved it.

Some pictures from the dealership of the issue are attached for context if it helps.

Thanks y'all!

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[RangerBill]

Hi everyone!

I've had a confusing situation come up and I want to understand what happened and how, whether I got hosed on the repair, and anything I should do to prevent it happening again in the future.

I have a 2021 Ford Ranger.

A couple of months ago, I got the alarm bell and the red "Charging System Service Now" indicator light. Pretty terrifying to find out that meant my truck should shut off any time while driving. I live in a mountainous area and that could be life threatening to me and others.

I brought it to my local Ford dealership two times and they couldn't figure out what the problem was. I brought it to O'Reilly Auto Parts and they scanned the battery and alternator and said they were both fine. The indicator light started coming on more and more frequently.

I made an appointment with another Ford dealership in the "big city" near me. They identified that the 225A fuse had broken, and said they had to change out the entire pre-fuse box. The cost for the part was $200 and with labor and "shop supplies" came out to $578. I just want to see if I got hosed for what maybe should have been just replacing a fuse that cost $12. It seems to be that if the entire pre-fuse box was replaced, this also neccesitated re-programming.

I also want to know why it happened. Perusing this forum and others, it seems that it could be the auto start-stop, maybe its the auxiliary lightbar I put on, and also, when I bought the car, the prior owner had put an after market blow-off valve on it. I'm sure there are many options, but I've also seen that the 225A fuse would need some sort of serious blow to pop. So I am wondering what you all think.

I am also very, very, nervous because, as you all likely know, people talk mad sh*t on Fords. This is my first one. I've previously had Subarus and Hondas and even when they were old beaters, I never had to do any repairs. For a '21 truck with 66k miles on it, I don't know if this type of issue is normal, or if I should be more worried that my truck has started its downfall and maybe I should try to sell it. I have otherwise loved it.

Some pictures from the dealership of the issue are attached for context if it helps.

Thanks y'all!

That fuse goes to your alternator. It should only require just replacing the fuse, without any other parts.

 

[RangerBill]

Where did you attach the power feed for your aux. light bar? If on that fuse stud, that may have been the problem.

 

[airline tech]

Ditto - On Ranger Bill, but however since it was not noted - If the stud or nut is not secured at the attach points (May) be the reason.

But I HIGHLY SUSPECT this is the reason as I have been there and done that.

I had to replace this fuse on another Ranger (my daughter's boyfriend) and when I called the dealer looking for a Part Number (For the Fuse) I was told I had to buy the whole assembly and the Fuse (WAS NOT) sold separately.

I promptly called another dealer and with some digging, he found a part number in the system which I then crossed over to a (Napa Autoparts) number.
I wanted to ensure a part number match) as no matter where I was part sourcing, the fuse had to be ordered, and he needed his truck, and the daughter needed a battery.
(so, both vehicles down) and they needed both. I replaced the battery for her and ordered the fuse.

As to why YOUR fuse blew? IDK, bad connection - possibly
or
In the case of my daughter - who needed a jump on her car, his Ranger was used with cables, and they connected to the stud of that fuse, for whatever reason it blew or partially blew (as I had) some voltage flowing through it.
Something like 13.5 on the stud and 8 on the other side. Visually it was GOOD

So, point is - you bought it used, unknown history - had it been jumped before, or had someone tapped for power on that stud. That fuse appears to be temperamental and can be partially blown (half burned) leg, once it hits a point that the truck sees a huge difference in charging performance it triggers the (IPC Message)

 

[FordCurious2124]

Thank you both! So, that reminds me -there is one more reason I suspect. I have a pump for my raft that runs off the battery. I certainly could have attached it to that stud in the past, as I would not have known it would be a problem.

As far as the light bar, I had my father-in-law install it, so I'm not sure where he attached it. The dealership said it was attached to "one side of the mega fuse."

 

[theprinceofsnj]

Ditto - On Ranger Bill, but however since it was not noted - If the stud or nut is not secured at the attach points (May) be the reason.

But I HIGHLY SUSPECT this is the reason as I have been there and done that.

I had to replace this fuse on another Ranger (my daughter's boyfriend) and when I called the dealer looking for a Part Number (For the Fuse) I was told I had to buy the whole assembly and the Fuse (WAS NOT) sold separately.

I promptly called another dealer and with some digging, he found a part number in the system which I then crossed over to a (Napa Autoparts) number.
I wanted to ensure a part number match) as no matter where I was part sourcing, the fuse had to be ordered, and he needed his truck, and the daughter needed a battery.
(so, both vehicles down) and they needed both. I replaced the battery for her and ordered the fuse.

As to why YOUR fuse blew? IDK, bad connection - possibly
or
In the case of my daughter - who needed a jump on her car, his Ranger was used with cables, and they connected to the stud of that fuse, for whatever reason it blew or partially blew (as I had) some voltage flowing through it.
Something like 13.5 on the stud and 8 on the other side. Visually it was GOOD

So, point is - you bought it used, unknown history - had it been jumped before, or had someone tapped for power on that stud. That fuse appears to be temperamental and can be partially blown (half burned) leg, once it hits a point that the truck sees a huge difference in charging performance it triggers the (IPC Message)

Not that I have this issue. But could you please share the part info? This might be a great help to someone in the future.

 

[FordCurious2124]

I don't know what the part info is beyond what I said. I guess I would appreciate it too!

 

[RangerBill]

The Ford part number is 6W9314A094AA. I found an eBay listing for a replacement:

https://www.ebay.com/itm/1829658433...1cnoknigSb7swQUeEEP1+Geg==|tkp:Bk9SR-yb88PPZA

 

[Rp930]

Thank you both! So, that reminds me -there is one more reason I suspect. I have a pump for my raft that runs off the battery. I certainly could have attached it to that stud in the past, as I would not have known it would be a problem.

As far as the light bar, I had my father-in-law install it, so I'm not sure where he attached it. The dealership said it was attached to "one side of the mega fuse."

Sounds like this problem was due to outside influence.

 

[FordCurious2124]

The Ford part number is 6W9314A094AA. I found an eBay listing for a replacement:

https://www.ebay.com/itm/182965843314?_skw=225+Amp+Fuse&itmmeta=01J9Y3WSQGW5YS7BY5CVAWVFR7&hash=item2a999d3572:g:dhEAAOSwRohk5nIo&itmprp=enc:AQAJAAAA8HoV3kP08IDx+KZ9MfhVJKnyr8/DRTS5Da3dcpgI2UGl0o79bbkgysBG+vXniLDrObo+hvqs4BJ4BVzJe43NKawATpXiyoqJWM92Jx1CHpPZaUuLbaZ0esXX+M13NDVtx3FHCrxB6KudWvNWRyje+zBHv/NvneQEtIFIdO3r0wOalYJwnv1uHz466cOQrGdYxPYk7vciRZcxfLcpUF1ZOX/Nxf6gG3wiGYDRJBhtX9eSUSUs5VRrq5CW9BZDUAzqDvnHeTQN9tkW7u3WWQJzeqITySY0/QccG+ieenId+A1cnoknigSb7swQUeEEP1+Geg==|tkp:Bk9SR-yb88PPZA

Thank you! Ugh that is really annoying. I hate to think that the dealership would hose me like that. I know that dealerships overcharge, but to replace a whole part that didn't need to be replaced and charge $200 for what should have been $12 seems insane. Do you know of any way they could have been right that the whole pre-fuse box needed to be replaced and reprogrammed?

 

[FordCurious2124]

Sounds like this problem was due to outside influence.

Yeah that's a bummer, so I'm trying to write it off as at least it was a learning experience and now I won't do this to someone else's car, and can educate other people. Thank you!

 

[RangerBill]

Thank you! Ugh that is really annoying. I hate to think that the dealership would hose me like that. I know that dealerships overcharge, but to replace a whole part that didn't need to be replaced and charge $200 for what should have been $12 seems insane. Do you know of any way they could have been right that the whole pre-fuse box needed to be replaced and reprogrammed?

I have no idea why anything would need to be programmed to replace the Battery Mounted Fuselink (BMFL) assembly. I couldn't find the Ford part number for the fuse listed on USA Ford sites, only on overseas web sites. I guess that is why the dealer replaced the whole BMFL.

 

[FordCurious2124]

I have no idea why anything would need to be programmed to replace the Battery Mounted Fuselink (BMFL) assembly. I couldn't find the Ford part number for the fuse listed on USA Ford sites, only on overseas web sites. I guess that is why the dealer replaced the whole BMFL.

Interesting...I wonder why.

 

[Grandaccess]

Yeah that's a bummer, so I'm trying to write it off as at least it was a learning experience and now I won't do this to someone else's car, and can educate other people. Thank you!

First rule, never do anything to your Ranger without coming here first!
to blow a 225 amp had to have taken a dead Short somewhere, I think even the Alternator only produces 140amp, I am pretty sure your light bar dont pull 225amp unless a wire got caught in the hood?
good thing it was there!

 

[Grandaccess]

This was a link in this page below of related
https://www.ranger5g.com/forum/threads/225-amp-fuse-popped.17459/

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