2020 Ford Transit Electrical System

My Balmar 2nd alternator on my Winnebago Ekko has just failed. This is a Winnebago installed electrical system component mounted in the Ford Transit chassis engine bay that provides electrical charging to the RV coach batteries. There was an initial NHTSA Safety Recall 23V-234 issued in 2023 after numerous Balmar units failed; in some cases the Balmar unit failure caused a fire in the engine bay. I had the Safety Recall work performed in July 2023 by authorized dealer Dennis Dillion RV in Boise Idaho per the attached invoice and the Balmar charging system had been working well until now. I am aware that there are ongoing reports by other Ekko owners of the Balmar alternator failures reoccurring after the Safety Recall work was performed, and in some cases even after Balmar 2nd alternators' were replaced, which suggests the initial solution provided by the Safety Recall was not sufficient to prevent a failure. Within minutes of starting to drive my RV today I noticed an unfamiliar whining sound from somewhere under the hood that I had not heard before and immediately checked my coach batteries while driving a short distance and went from the batteries discharging significantly to not charging at all. I opened the engine hood and had smoke visible and a strong burning smell coming from the passenger side of the engine bay where the Balmar unit is located. I was very concerned about the potential for an engine bay fire, but fortunately was very close to my home, so my RV is now parked in my driveway. See attached screenshots showing the initial voltage discharge while driving and then the batteries not getting any charge while under power. Also attached is the Recall 23V-234 repair instructions. I plan to unplug the Balmar alternator to prevent the potential for a fire while awaiting a response from Winnebago how to proceed. Despite the NHTSA Safety Recall having been performed, there are reports of alternator's failing and risk of vehicle fires remains.

The van will not start on a regular basis. Usually within a week the battery voltage has depleted to the point the van will not start. Have to put a charger on it often. This is a commonly reported problem on many forums.

The battery's junction box in the engine compartment is melting. While I was driving, I heard a loud pop, I opened the hood, and saw smoke coming from the junction box. I noticed the box was melting around a fuse. The melting is significant, and the vehicle looked to be on fire. The smoke stopped, but I feel the vehicle could easily have caught on fire completely. There are recalls for this same exact issue but for other Ford Models. I have a fleet of these vans, and this has now occurred to 6 of them. I know other owners that this occurred to as well. I have called Ford Goodwill and they have declined to cover it under the 3-year, extended warranty. The melting was so bad on one that the actual harness was burnt as well. This is a dangerous issue that Ford already knows this happens. I have receipts for all of these repairs and the technician acknowledging the junction box melting. I have emails from Ford where they apologize for the issue, and they say they cannot cover it under warranty. They refuse to comment on the safety danger this poses on all. This is an amazon delivery van and there are thousands of these that could catch fire in someone's house or business.

Left the van running in my driveway next thing I know it was on fire

VAN WAS STATIONARY ON STREET AND FAILED TO START TWO TIMES, BATTERY WAS FULLY CHARGED.