Wondering if the second version of the BCC recall was done...

[AxialFlux]

So it looks like my chassis battery is not being charged while on shore power, and also my emergency start switch does not seem to work. I did email Thor to see if the BCC recall had been done, and they said that all recalls had been done, but perhaps they only did the initial BCC recall, and not the 2nd version. Would that cause my issues? This is what my BCC box looks like, which does not match what I have found online.

[javelin]

Just doing a “quick look” at your BCC external wiring picture, it looks like the original “chassis switched” cable was moved off its labelled terminal and onto the chassis battery terminal as specified by the recall, but then someone has placed the red shorting cable between the chassis battery terminal and the chassis switched terminal......which I “think” basically bypasses the chassis disconnect relay main latching contacts inside the BCC. So this would “probably” mean that the loads controlled by the chassis disconnect relay (like steps; dash loads – blower motor, etc) could not have chassis battery power disconnected, using the chassis disconnect switch at the door (which operates and releases the chassis disconnect latching relay), when/if required. But, it also means (if I am correct) that if the chassis disconnect relay ever fails, those loads will still have power from the chassis battery (if the battery is good, etc.). So it is probably OK as wired depending on how you want to control those chassis loads. I am not sure if the gauge of that red bypass wire is suitable for the loads or not though; should match rating of contacts on the latching relay I would think.


So, your described trouble sounds like possibly the interconnect relay (silver looking relay connected between the bus bars) has failed open; or worst case the circuit board in the BCC that allows operation of the interconnect relay has a problem. I would guess the interconnect relay would be a good starting point to check out. I am attaching some pictures that may help. There are also documents on line with descriptions of how this BCC operates; troubleshooting etc and a very good youtube video of opening up the BCC and describing it. Hope this helps a bit.

[AxialFlux]

I guess I am confused, as per the "update" recall, the cable from the Chassis Switched terminal was moved to the Chassis Battery terminal, and I still have cables on my Chassis Switched terminal.

[John & Diane]

Go to RV Custom Products https://rvcustomproducts.com/ . Under products, go to FW-2050 and download the file named 13V-265, which will give you info on the recall and the correct fix. If that doesn't answer your questions their customer service was very helpful when I had an issue wit my batteries not charging. I have a TH-1020 BCC in our 2015 Windsport. my problem turned out to be a bad ground connection to the frame in the coach battery compartment. Phone # is 562-921-8353. Good luck.

[javelin]

Hi. Technically you should be able to remove that red cable (with due care and attention - all battery grounds disconnected and taped; no SP; no gen) from between the chassis battery post and the chassis switched post on the BCC, as long as your chassis disconnect latching relay is working properly. Then, in order to power many of the electrical loads still connected to the chassis battery, through the chassis disconnect latching relay, you would have to operate the “chassis disconnect” switch located near the entrance to your coach.

The Thor recall, by moving the original chassis switched cable over to the chassis battery post, basically hard connected many of the critical Ford chassis loads to the chassis battery. This was done because if the chassis disconnect latching relay inside the BCC failed open at any time, (eg., the engine could die going down the road at night, with loss of lights and other critical systems). I am assuming a previous owner, or whoever did this recall also added the red wire, I assume, to make sure that if the chassis disconnect latch relay ever failed after the recall, the other electrical loads still connected to the switched side of the latching relay would remain powered.

I am not sure why you mention a “second recall”, as I thought there was only the one recall, unless I missed something. I know some folks just left the original factory cables attached to the BCC terminals and then jumpered across (like your red wire) with a large gauge battery cable. Technically it satisfies the recall, but also makes the “chassis disconnect” switch at your entrance door useless. Makes disconnecting the chassis battery from its remaining switched loads more difficult, if you want to do that.


Regarding your described trouble though, if you look in the top left corner of the schematic I attached previously, the top two terminals down the left side are where the chassis battery (top) and the coach battery (next one down) attach to the BCC. You will note that there is an open relay contact shown between those two connection points inside the BCC on the schematic. That is the “interconnect relay”, which under certain conditions closes to connect the chassis and coach batteries together for joint charging and for emergency starting. So it also closes when the driver operates the emergency start switch (if everything is working OK). I suspect that silver relay (interconnect relay on the schematic) in my previous pictures, is your problem, or related wiring/connection that normally operate that relay. I don’t think the red wire is responsible for this trouble. If you do not have electrical experience though, I would caution you not to go into the BCC with any battery grounds connected and even be very careful working on the exterior of the BCC. Serious electrical problems could result if you are not careful here. If you find you have to replace the interconnect relay, I would leave that to someone with the electrical experience to do so. I think Thor would just replace the whole BCC through a Dealer for big bucks; you probably can buy parts on line from the manufacturer or Amazon, but need the electrical safety knowledge to replace it. Look for the documents and video on line that I suggested in my first post and through testing procedures, you may find your problem is just a loose interconnect relay control connection somewhere.

[AxialFlux]

Thanks for the info. What I meant by "second recall" was the revision that modified the original recall. I did check both, and it seems the initial recall was done, but not the revision. I don't think that has anything to do with my issue though, and more than likely, it's the relay that is at fault. I do have some electrical know how, and may look into it down the line, but as it is, it's not anything that needs fixed ASAP.

[javelin]

Thanks for clarifying the two BCC recalls AxiaFlux. I purchased our 2013 ACE new in Sept 2012, but the only recall notice I received was the final “corrected one” released in July 2013 I think......which places both power cables on the Chassis Battery terminal of the BCC. So your picture shows the correct final placement. The red strap is an add on, probably done by previous owner for reasons discussed already. By the way I do carry a short commercially purchased battery strap in my spares stock so in case the chassis latch relay fails, I can simulate your red strap as an optional bypass. I normally leave my coach and chassis battery switches on all camping season, since we rarely boondock and we are always on SP when camped/parked at home. Less wear and tear on the latching relays, which are a PIA to change in this BCC. Happy camping.