HVB high voltage battery contactor stuck and Lightning went into protect mode

I have driven my Lightning approximately 9,200 miles so far and ran across my first major issue.

The other day I went to start the truck to go to work and it wouldn't go the "ready" status. When I pressed the start button the truck would wake up and then display an error message stating "pull over now" and a little truck symbol is an exclamation point in the bed. Looking through the manual there isn't even a symbol that looks like what I experienced.

Got the truck to the dealer. They put it on the computer and it states the positive high voltage contactor is stuck. The truck went into protect mode because of this. They removed the battery from the truck and sure enough the contactor needed to be replaced. Ford emergency shipped the part to the dealer and they are currently installing the new module.

I was able to get a few pictures of the battery without the cover on. There are 8 modules that show 16.44kWh on the sticker and there is an additional battery module that shows 12.xxkWh. I have read from previous posts that the battery is larger than the stated 131kWh capacity and this confirms it!!

All in all it sucks the truck had this issue but Ford took care of it immediately and I am satisfied with the end result.

Glad that things worked out for you. Potential electrical and mechanical problems are the price of being early adopters. It’s interesting that the eight 16.44 kWh batteries come to 131 kWh. Maybe the 12 kWh is the “extra”.

Glad it’s being resolved quickly. Any pics of the underside of the truck with the battery removed?

Tony Burgh said:

Glad that things worked out for you. Potential electrical and mechanical problems are the price of being early adopters. It’s interesting that the eight 16.44 kWh batteries come to 131 kWh. Maybe the 12 kWh is the “extra”.

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Probably…a previous thread noted the ER HVB has a total capacity of 143.4 kWh…the math (143.52) pencils out………..

This seems to be the second HVB contactor issue reported for Lightnings. I hope this isn't the same issue that is plaguing Mach-e owners.

kwalt21 said:

Got the truck to the dealer

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Thanks for sharing. Did dealer picked up the pickup? Or you used your own towing company? Was there anything tricky about getting it to the dealer?

sotek2345 said:

This seems to be the second HVB contactor issue reported for Lightnings. I hope this isn't the same issue that is plaguing Mach-e owners.

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I think it may be the third one reported here, but I’m too lazy to look for the threads.

Maquis said:

I think it may be the third one reported here, but I’m too lazy to look for the threads.

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Regardless, I'm not worried yet, but will definitely keep a lookout for similar stories

Thanks for sharing..

I moved the thread to the TECH > Issues....... node.

Maxx said:

Thanks for sharing. Did dealer picked up the pickup? Or you used your own towing company? Was there anything tricky about getting it to the dealer?

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Good question, and loaner/rental options?

Anybody cross reference the part numbers for the contactors? Does anyone know who made the contactors? Great pics btw. I find it encouraging the pack can be removed and opened easily to work on. I wonder where the pack cooling is located?

Guess I’m glad the battery is indeed relatively quick to remove. Thanks for sharing!

Oh wow! I just picked up my MME today for the HVBJB contactor replacement and now I come across this possibly for my Lightning

you have better pictures than Munro Live. Will they be replacing the battery Mounts as well?

Side tracking a little here. Is anyone else experiencing an audible “click” when taking off from a standstill. Sound appears to be front driver side, my guess would be a contractor closing.