I have a 200 amp 2014 Limited 3.5 L Explorer with 189,000 miles. Last year a light came up that said "Charging system fault". My wife said she had sèen that 2 x before. I noticed that the steering felt different. Turns out, Ford programmed the car so the Electric Assist Steering shuts down if you ignore that warning, and it will do it at highway speed. It did. We were fortunate to get off the road without wrecking. Shut the car off and it locks up for good. Ford then says you have to replace the whole rack and pinion steering unit. So I got one, installed it, had it programmed, bought a new battery, and for under $1,000.00 got it going again. I suspected there was nothing wrong with the original, so I kept it.
This year, the same thing happened. Warning light: "Charging system fault". Steering wheel hard to turn. This time I was close to home. (¼ mile) Went home, shut it off, restarted, sure enough, steering completely locked up. Battery (850 cca) was indeed low. Belt looked cracked, so I bought a new parts house aftermarket tensioner and Gates belt. Their computer called for a 45⅛" belt. It went on, but it was a fight. The tensioner stops are practically touching, and they do touch when you rev the engine briefly, chattering for a second or less. That belt is too short. But, I trickle charged the 10 month old battery, and, vìolà, no more code, and the steering works again. Went back to the parts house yesterday with the VIN, and now they have 2 entirely DIFFERENT belt lengths showing for a 200 amp limited explorer, 2014 3.5 L. I came home with a Gates 45¾ inch belt, per the new info on their computer. As soon as it is light enough to see, I will try installing it. It never occurred to me to replace the tensioner, but I talked to an honest friend who told me that a new tensioner and belt solves the "charging system fault" warning/electric assist steering shutdown issue 95% of the time. And for less than $75 bucks. I am going to suggest the likely possibility that Ford Motor Company programs the steering shutdown into the software on purpose, and that the Electric Assist Steering/Rack and Pinion Steering assembly is fine.
I dissambled my original rack and checked it. No leaks, no binding rack, no damaged belt, no visible damage anywhere. Electric motor that turns the tiny cogged (vacuum cleaner looking) belt, works, so I have to question the motivation of FoMoCo for justifying programming into my car's computer an EXTREMELY DANGEROUS and potentially DEADLY steering wheel lock-up that can and DID occur at highway speed. EVEN IF the circuit board fried on the rack and pinion itself, you just MIGHT still need to use the steering wheel, don'tcha think? I have never seen such engineering idiocy in my 64 years. A power steering pump is all you need. You do not need $20,000.00 worth of high tech cameras and electric steering. You do not need to be able to take a nap or take your hands off your steering wheel while driving your car. We do not need cars that drive themselves. We need simple, safe, and reliable. We need the non-drivers to take the train. And Ford needs to be held accountable for this fraudulent scheme to sell unnecessary steering parts and then "program" them for as much as $500.00. How many crashes have there already been? And where is there ANY consumer protection agency looking out for US? As my old Granddad would say 50 years ago, "This world is going to hell on greased skids."