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BMW PHEV: Safety fuse replacement is extremely expensive

evclinic.eu

191–200 of 548 posts

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#191
post #2

This is exactly why I’m so uninterested in driving en EV. I usually word it as “I don’t want to drive a computer”, but the reality is that I don’t want to be on the wrong end of the power imbalance that comes from this amount of complexity.

The problem of repairability and independent garages to have access to the tools, software and training to repair cars is not specific to electric cars. The level of electronic and automation is related to safety norms which applies to any car.

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#192

Earlier quoted context omitted.

Yet somehow adaptive cruise is a rarity on the BMWs out there, often requiring an option package that few dealers spec. (Though I think this may be finally starting to change with the 2025 model year).

Sadly, they’re close to 100% caught up to automatic transmissions in North America.

Are you advocating for manual transmissions?

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#193
post #2

This is exactly why I’m so uninterested in driving en EV. I usually word it as “I don’t want to drive a computer”, but the reality is that I don’t want to be on the wrong end of the power imbalance that comes from this amount of complexity.

PHEVs are particularly complicated because they have to support two drive trains. Just EV’s are very simple outside of the battery management. It’s power from the battery going to a motor.

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#194
post #166

Earlier quoted context omitted.

Is it insane? I'm working in this field, and I know how quickly you can come up with such a number if you are BMW and you are deathly afraid that someone will get electrocuted while working on your car, driving it or rescuing someone in a crash. It's a safety and liability issue, where they go to great lengths to actually re-certify a battery after crash. The whole thing is setup so, that even the dummy electricians…

The article and comment aren't debating whether the fuse plays an essential role. There's no reason to make the process of fixing the issue after a minor incident expensive, extremely convoluted, and very prone to error. Making it a very complicated and expensive fix isn't what's saving your rescuer or mechanic from getting electrocuted while working around your car.

> There's no reason to make the process of fixing the issue after a minor incident expensive, extremely convoluted, and very prone to error.

Yes there is. Either nobody is engineering towards that aspect or it is a conscious decision, deliberating between two different buckets: bill-of-material cost per unit and estimated impact on your warranty & goodwill budget. Whatever is deemed to be cheaper will win.

Source: I work at an automotive OEM and one of my first projects almost two decades ago was how to anchor after-sales requirements into the engineering process. For example, we did things like introducing special geometry into the CAD models representing the space that needs to be left free so a mechanic can fit his hands with a tool inside. These would then be considered in the packaging process. If you consider these are two completely different organizations, it becomes a very tricky problem to solve.

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#195
It seems to me an analogy that as a product is increasingly complex, the ultimate consumer/demander of it becomes more and more disconnected from maintenance, operations, etc. considerations and whether that system is well designed and serviceable.

Cars of a past generation were able to be owner-maintained (or understood), and therefore the owner had some interest in knowing that it was easy to maintain and would buy (at least partly) on that premise. Something that was a nightmare to maintain would not be so easily bought because the owners would soon realize how hard they were to fix.

Now, with a car that is so complicated, the owner is far distant from being the fixer of it until years later seeing a surprise repair bill. Even the maintainers are not even directly knowledgeable about the design and how to repair. And the information about its maintainability is a low factor on the buying considerations list. But by then you've already given the company the money and incentive to keep on building this way. And rarely (or extremely/too "laggily" does that information feed back).

It seems to me enterprise software systems have this problem as well.

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#196

The article misses to explain why this is an EU problem, not just a BMW problem. Is the problem described caused by a specific EU regulation (which?) or is mentioning the EU just click bait? (Honest question.)

What they mean by the EU-bashing is two things:

1. The EU de facto mandates the car manufacturers have to develop and sell cars that produce less CO2 (mostly by the way of fines for higher polluting vehicles). This led to the development of hybrid ('mild-hybrid', 'full-hybrid', and PHEV) and EV vehicles.

2. The manufacturers tend to both complicate the technology and lock the stuff down, so it's not easily repairable. This has its own enviromental price, and EV Clinic says this is not accounted for. That's not completely fair as on one hand there are EU repairability directives that address this but on the other we still want to have some degreee of market competition and in the end the market should punish those manufacturers (as it is already doing, I think).

One thing I want to add is that the EU also mandates real-world-fuel-consumption-measurement (OBFCM) devices in new cars and if that is followed to its logical conclusion and the manufacturers pressure is resisted, this will mean the end of hybrids as the real-world data is horrible for them.

https://zecar.com/reviews/plug-in-hybrid%27s-real-emissions-...

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#197
post #194

Earlier quoted context omitted.

The article and comment aren't debating whether the fuse plays an essential role. There's no reason to make the process of fixing the issue after a minor incident expensive, extremely convoluted, and very prone to error. Making it a very complicated and expensive fix isn't what's saving your rescuer or mechanic from getting electrocuted while working around your car.

> There's no reason to make the process of fixing the issue after a minor incident expensive, extremely convoluted, and very prone to error. Yes there is. Either nobody is engineering towards that aspect or it is a conscious decision, deliberating between two different buckets: bill-of-material cost per unit and estimated impact on your warranty & goodwill budget. Whatever is deemed to be cheaper will win. Source: I…

It's like the manufacturer discovering to their complete surprise they are building a car. :-D

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#198

Not just BMW. I've been watching (and enjoying) Mat Armstrong's youtube videos where he restores crash damaged luxury cars, one of them was a Lamborghini Revuelo. The car's battery was completely intact, but the safety fuse blew up in the BMS and despite replacing the entire module, the car wouldn't talk to the battery and wouldn't even start. Eventually he had to buy an entire 30K battery, and even then, the car wou…

Interestingly I’ve seen YouTubers replace the fuse in a Tesla for about £40 and a few hours of labour (it’s under the rear seats). Maybe something they’re doing right.

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#199

Earlier quoted context omitted.

Is that $10k the list price, or have you actually seen a recent invoice from a mechanic for a Model 3 battery swap?

I was quoted $15k in a Tesla service center for a Model 3 battery replacement, with parts and labor.

Wait another year. CATL is destroying the battery market with their new LFP and sodium batteries. Prices are collapsing.

Re: BMW PHEV: Safety fuse replacement is extremely expensive

#200

Earlier quoted context omitted.

Talk to car guys who are into ~2000s era or before cars. They usually have pretty solid recommendations.

Most people need a recommendation for something more current, from people who work on these modern cars daily. The reputation of 25+ year old models can be misleading. Another source of good recommendations could be insurance companies. Cars with low reliability or very expensive fixes probably need more expensive insurance. But I don't know if this data is public or if you can tell apart the reliability from the rep…

If you're in Europe, you can consider Dacia. A lot of their stuff is old Renault parts that they've bought a license to use/manufacture. Get a pre-2023 model with the 1.6 non-turbo non-hybrid petrol engine - it's actually a Nissan HR16DE, which has been in use since 2004. Very reliable and low complexity.
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