Crowd-sourced diagnostics!

I recently sent out a help request for diagnosing a car that intermittently dies while driving. I’ve attached two files of the CAN data covering two occurrences of the car spontaneously shutting down. If anyone can find the key to why the car shuts down, I’ll buy you lunch!

Data1

Data2

Here are some charts of Data2: The first one is all of the data and the second one is zoomed in to just the area surrounding the BUS HEAVY error.

Chart1

Chart2

I simply sorted the message IDs and assigned them integer values. Here’s a key:

ChartMsgID_Key

(They’re not exactly in order because the spreadsheet got a little bit confused by the hexidecimal numbers, thinking they were text.)

Indemnification

I would prefer to repair all the Thinks in the world with my own labor at a reasonable price. But I’m afraid traveling to the locations of all Thinks that are in need of repair would not be feasible unless the price was wildly unreasonable.

So I will provide the best advice that I can to anyone that chooses to take up the challenge of Think repair. By accessing the advice on this website you agree to not hold me liable for any damage or injury that may result from attempted repairs or maintenance. Continue reading Indemnification

Water infiltration in the low voltage traction battery wire harness

The circular plastic connector that plugs into the traction battery is fitted with heat-shrinkable tubing lined with adhesive which makes a pretty good water-tight seal between the connector body and the plastic loom that protects the wire harness. Unfortunately, the upstream end on the wire harness often leaks, and the seal only serves to hold the water in. The connector includes a rubber weather-pack around every single wire, but because the harness slopes up, the water in the loom is pressurized by gravity and eventually works past the seal and causes galvanic corrosion. I have seen a few cases in which pins actually broke off inside of sockets and could only be removed using a specialized tool: a paperclip.

I don’t think that the water that gets into the connector goes on to enter the battery– I don’t think any pressure would build up on the weather-pack on the bulkhead-mounted socket, the battery-side of the connector. But water definitely finds a way in through other flaws in the battery case seal.

IMG_20160607_125311

IMG_20160607_125433

Every Think that I have ever done any battery work on has that heat-shrink broken loose from the connector to allow water to drain.

Think Service Centers

Here’s a list of Think service providers that I’ve taken and modified from Jim McL’s blog:

http://minie458.blogspot.com/2012/04/service-center-summary-for-think-evs.html

I’ve made a few updates, but maintaining and revising this list will be an ongoing process. Please let me know your experiences with your local shops so that other Think owners in your area can benefit from your wisdom. Continue reading Think Service Centers

Zebra -> Enerdel retrofit photos

You can see there is just a large hole cut in the web of the frame where the traction battery cables go through. Below is the bracket/box/cover that protects that hole from from weather, but does not seal it out completely; it mounts on 4 studs on the frame. Good luck, Nikolay!

ThinkWithTractionBatteryRemoved

IMG_20160822_103719

Trying to get in touch with Enerdel; UPDATE: Disappointing Success

Here is the response from Enerdel:

From: Battery Support <support@enerdel.com>
Date: Fri, Jun 17, 2016 at 7:22 AM
Subject: Inquiring on Think City Car
To: “john.mayer@greendropgarage.com” <john.mayer@greendropgarage.com>

Thank you for Inquiry.

We are sorry for your inconvenience, however, we no longer provide
replacement parts for the Think City Car.

Continue reading Trying to get in touch with Enerdel; UPDATE: Disappointing Success