Battery Monitoring System Wiring Harness Chafing and Fire Hazard
SeriousElectrics & ElectronicsOn Ka+ models manufactured between September 2017 and May 2019, an incorrectly routed and unfused wiring harness lead for the Battery Monitoring System (BMS) can become pinched beneath or rub against the metal battery tray and retaining bracket. Continuous vehicle vibration wears through the wire insulation, creating an unfused dead short to earth against the chassis. This triggers a serious safety hazard resulting in smoke, harness melting, and potential under-bonnet fire. Ford issued safety recall 19S21 (DVSA recall R/2019/189) where technicians inspect routing, wrap the harness in protective abrasion-resistant tape, and secure it with a revised retention clip.
Illuminated battery charging warning light or random instrument cluster warnings, Acrid burning plastic smell or visible scorch marks around the 12V battery tray, Intermittent auto start-stop system deactivation or sluggish starter motor cranking, Blown auxiliary fuses or sudden loss of electrical power to dashboard accessories
- Inspect the negative battery terminal and BMS sensor harness for protective cloth tape and secure bracket clearance
- Check the vehicle service record and MOT/DVSA database to verify safety recall campaign 19S21 has been signed off
- Look for signs of copper conductor exposure or rubbing marks where the wiring runs past the battery securing strap