Urgent Help Needed with Transit Battery Issues Post-Welding

[EdRedBird]

Hey everyone,

I have a 2010 Ford Transit that recently failed its NCT/MOT and needed a bit of welding work. I've driven it about 100 miles since getting it back. Last night, I noticed a burning smell inside the van. After checking twice and not finding the source, my passenger accidentally dropped a water bottle, and when I picked it up, I realized the box under my seat was hot.

Thinking there was a short circuit, I disconnected the DC controller and waited for a bit. The van started up, and the housing seemed to have cooled down. However, once I got to a safe spot, I realized the battery was bubbling, crackling, and leaking. I removed the seat and took out the affected battery. My Transit has two batteries, but it ran fine this morning with just one.

Now, I have a few urgent questions:

1. What could have caused this issue? Is it likely related to the welding work?
2. Could the parallel battery also be damaged? I checked it during and after the drive this morning, and it seems fine.
3. The DC to DC controller appears to be in good shape. I suspect it would have failed before causing damage to the house batteries (which are flooded), as they're wired to the common negative on the controller and not the chassis. Does this make sense?

Any insights or advice would be greatly appreciated! Thanks in advance.

 

[activecampers]

Whats the voltage at the battery with engine running?

Possible the alternator/regular has failed and pumping out too many volts, and this could've failed/been frieed if battery was not disconnected for welding.

Was the battery disconnected when they welded (clocks wrong etc?)

Not sure why you have 2 vehicle batteries? Is this a hang up from original base? If so it may be possible they saw one battery,disconnected it, and didn't see the other? Odd but being generous

 

[David and Sally]

I presume you mean a starter battery? It could be due to welding or simply knackered. How old is it?

 

[Barriesimpson]

Well if the batteries were not disconnected before welding then the welder has cooked them and they need to be thrown away and replaced. Basic safety regulations to be honest.

 

[Lenny HB]

One battery is the starter battery the other one runs the cab electrics quite common on Tranies.
I would fit two new batteries.

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[oldiesontour]

It may be possible in theory to damage regulator and or other electrical items when welding(electric) with battery connected,but in my experience has never happened to me and I've done lots over many years

 

[Outdoors Dad]

I have a transit, both starter and hab battery under the seat. I've recently changed starter battery. I would re-new starter battery (£90). Whilst your on I'd fit a lithium (£200ish) behind seat and free up space for wiring it's beyond cramped in there.

 

[DavidG58]

I presume it must be the habitation battery that has failed as if I read correctly it has started since removal

Hopefully just run its course, if it is as old as the base vehicle it has done very well

 

[The Wino]

The first thing that springs to my mind is if they have welded near a wire and melted the insulation causing an intermittent short.

 

[ianp]

By the sound of it you've had a cell go down in the knackered battery and as such it can never reach it's 'charged' voltage and so the charger just keeps pumping energy into it until it boils......this assumes that the other battery is fed from the same charging sources.....hence likely that the 'control' of the charging sources is ok as that battery is OK. A cell failure is a common failure mode in any battery especially aged ones......replace the battery with another and monitor for a week.....no big deal !

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[DandG5515]

Does depend on the model of transit mine is a 2009 2.4 rwd it has 2 engine batteries under the driver's seat and 2 hab under passenger seat. However mates 2.2 fwd has single engine battery under driver's seat.