NHTSA ID Number: 11012622
Manufacturer Communication Number: Motiv TSB-Radlok
TSB/Document Date: 2025-01-08
Summary
Motiv Power Systems, Inc. has determined that on certain vehicles converted to a Motiv EPIC4 E-450 electric powertrain, a 12-volt power wire connection point could loosen over time, potentially resulting in loss of connection and loss of 12-volt control power to the High Voltage batteries
. This, in turn could result in a loss of vehicle propulsion. Motiv has not received any complaints or reports of vehicle crashes because of this issue; therefore, Motiv considers this as a proactive measure to protect the public and Motiv’s customers from the potential risk associated with this defect.
Motiv Power Systems
330 Hatch Drive
Foster City, California 94404
November 18, 2024
Re: Motiv Technical Bulletin for the following recall notices
•
•
24v781 - Connector Retention (Non School Bus)
24v782 - Connector Retention (School bus)
•
2024-627 - Connector Retention Transport Canada)
RECALL INFORMATION
Motiv Power Systems, Inc. has determined that on certain vehicles converted to a Motiv EPIC4 E-450 electric
powertrain, a 12-volt power wire connection point could loosen over time, potentially resulting in loss of
connection and loss of 12-volt control power to the High Voltage batteries. This, in turn could result in a loss of
vehicle propulsion. Motiv has not received any complaints or reports of vehicle crashes because of this issue;
therefore, Motiv considers this as a proactive measure to protect the public and Motiv’s customers from the
potential risk associated with this defect.
To ensure that these vehicles meet Motiv’s stringent quality requirements, follow the instructions outlined
below to inspect all potentially affected vehicles and correct or replace any 12-volt control wires showing signs
of fatigue, cracking, or improper retention or protection.
VEHICLES AFFECTED
Ford E-450 Motiv Gen 5 EPIC4 produced between 1/1/2021 and 9/30/2024
VEHICLE QUANTITY
There are 122 vehicles affected by this recall (65 U.S, 57 Canada).
PROPRIETARY AND CONFIDENTIAL
Pg 1
| The information presented here may be subject to change at any time. |
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© 2023 Motiv Power Systems
Motiv Power Systems
330 Hatch Drive
Foster City, California 94404
REPAIR INSTRUCTIONS
1. Locate the master disconnect switch under the hood.
2. Turn the mater disconnect switch to the OFF position and wait for five (5) minutes for the vehicle to
completely de-energize.
3. Disconnect the positive lead to the 12v battery.
4. Remove 3.6mm Radlok cable. It’s the smaller Radlok cable that goes from the Wurth fuse box to
the DC-DC. Completely remove it from the truck. Cover the now exposed Radlok pin with heat
shrink.
PROPRIETARY AND CONFIDENTIAL
Pg 2 | The information presented here may be subject to change at any time. |
|
© 2023 Motiv Power Systems
Motiv Power Systems
330 Hatch Drive
Foster City, California 94404
5. Install new “unswitched” power cable for fuse box – P/N 840-115034-024. Unplug P75 (purple
leavyseal) from Wurth fuse box. Remove back shell. Remove clear plug from position 17 on P75.
Disengage yellow TPA on P75. Insert MCP 2.8 end of new power cable into position 17. Reengage
yellow TPA. Reinstall back shell.
6. Install M8 ring terminal end of new power cable on the positive terminal of the 12V DC-DC – tighten
to 13 ft/lbs. Use zip ties to secure power cable to existing harnesses.
PROPRIETARY AND CONFIDENTIAL
Pg 3 | The information presented here may be subject to change at any time. |
|
© 2023 Motiv Power Systems
Motiv Power Systems
330 Hatch Drive
Foster City, California 94404
7. Inspect Wurth Box Fuses on locations for Battery 1, 2, 7 and 8 to make sure those are not blown.
8. Reinstall the positive lead to the 12V battery.
9. Turn on red switch.
10. Turn on key.
11. Test drive vehicle.
PROPRIETARY AND CONFIDENTIAL
Pg 4
| The information presented here may be subject to change at any time. |
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© 2023 Motiv Power Systems
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TSB/Document ID: Motiv TSB-Radlok
Replacement Service Bulletin Number:
MFR Communication Date: 2024-12-24
MFR Internal Campaign ID/Software Version: 24V781
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System: Electrical
MFR Component Subsystem: Electrical Distribution
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