Powertrain Malfunction/ Reduced Power

[TaxmanHog]

DONE

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[Pete22569]

Is it Ford that isn't standing behind their product, or your dealer? Corporate seems locked into having dealers....

Finally got the diagnosis done (after 2 days sitting at the dealer). They say I have a bad High Voltage Module and ordered the parts….

i had to rent a car (and pay out of pocket) until the diagnostics. They have now provided me with a Dealer Rental ICE Bronco, but charged me $100 for some reason even though Ford approved the rental under warranty.

So now I have to pay for gas while paying for an EV to sit at the dealer.

I hope they get it fixed fast and right.

 

[Zprime29]

So now I have to pay for gas while paying for an EV to sit at the dealer.

I hope they get it fixed fast and right.

Fingers crossed for fast shipping. Seems like it take about a day, sometimes two once they get the module. Depends on how long it takes to get the new module balanced with the rest of the pack.

I seem to recall some people reporting that they where reimbursed for gas while waiting on this repair. Keep your receipts and reach out to the BEV team about it. I can't recall which thread I saw it in at the moment. Might be worth doing a forum search and message the person for more info.

 

[LazyLightningATX]

Advisor called today and says they received my modules and hope to get the truck back to me tomorrow. Seems like it took about a week for the modules to arrive. Trucks been in for 16 days now...

 

[LazyLightningATX]

Advisor called today and says they received my modules and hope to get the truck back to me tomorrow. Seems like it took about a week for the modules to arrive. Trucks been in for 16 days now...

Asked for an update this morning and somehow in less than 24 hours my truck has gone from tomorrow to Thursday. "This battery is so big we are using 2 guys" he says. WTF is that supposed to mean?? If servicing a battery "so big" was going to be a problem, then THAT is a problem!! Also, my app is telling me my truck hasn't MOVED from their parking area in 2 weeks, so....

 

[Pro or NO]

Uh oh.. Looks like I might be joining this club. Powertrain malfunction after work. 95% power from work to the dealer. Dealer cant check it out for a week. Wrench disappeared going from the dealer to home but power went down to 91%. Put it on the charger and now everythings is OK... We'll see what tomorrow brings. At 170 miles.

 

[LazyLightningATX]

Looks like my truck moved into a garage this afternoon. Guess they are finally actually working on it!

 

[dgargano]

Hi folks, thought I would give you an update. I lucked out for two months without any more warning lights. However ten days ago I saw a High Voltage Battery Warning (Electrical Fault) and Powertrain Malfunction lights and the truck lost 90% of its power. I was just coming off the highway and was able to limp home doing about 20mph. When I called Ford dealer this time they were very accommodating. They towed my Lightning to dealer and also dropped off loaner Mach e GT. Service tech said that battery module #9 needs replacing and Ford was sending one out to dealer. But it's gonna be a few week turnaround to get this fixed.

Definitely frustrating but at least I have a rental this time (I just don't think I'd purchase a Mach e, lol). I have mixed feelings about this whole ordeal. I get it, Ford over promised here, ran into supply chain, resourcing, and service station issues, and possibly released to market too soon, but seems like that's what automakers do right. I do feel like many BEV makers (besides Tesla) will be in the same learning curve boat as Ford. I really won't defend Ford here, there's lots of room for improvement. But I'm confident Lightnings will get better, and their batteries and software will get better. Its the new world we live in, and as an early adopter I'm patient and manage my own expectations daily. I continue to love my Lighting, best truck and vehicle I've owned. Thanks for listening folks. Keep you posted.

My final update for this issue folks. So Ford had my truck in shop for 19 days. They replaced the bad battery module and also completed 4 other safety recalls from letters I received in mail (rear light bar wiring, steering wheel wiring and heated grip, and a few others software updates). I read somewhere that it can take days (thought I read up to 22 days) for new battery module to sync with rest of modules and gain its efficiency back to 100% charge/max mileage. I haven't charged my truck yet since back from dealer but if I have any issues will keep you all updated. This ordeal has been frustrating for sure but I'm glad to have my truck back. As I've said before I don't mind being an early adopter and don't mind some inconveniences but I just don't want this to become a regular occurrence either. I'm curious as to percentage of Lighting owners that are experiencing similar issues but Ford probably doesn't have data on that yet. I'm still bullish on Lightning, this truck is really bad a$$. I expect Ford will work out its bugs and do right by all Lighting owners. Happy holidays everyone.

 

[dgargano]

Uh oh.. Looks like I might be joining this club. Powertrain malfunction after work. 95% power from work to the dealer. Dealer cant check it out for a week. Wrench disappeared going from the dealer to home but power went down to 91%. Put it on the charger and now everythings is OK... We'll see what tomorrow brings. At 170 miles.

eek, crossing my fingers for you

 

[Zprime29]

I'm curious as to percentage of Lighting owners that are experiencing similar issues but Ford probably doesn't have data on that yet.

There was a CSP for the battery modules (SW update to monitor and not brick the truck if one goes bad) that said 4%.

 

[massmedic]

I had posted on another thread so just copying and pasting here as well.

Alright, I have my follow-up. Picked the truck up from the dealer yesterday (33 days at the dealer).

They took care of the battery fault, the dash mat, and the rear lightbar in one visit. They had a heck of a time with the high voltage battery troubleshooting on my end. This looks like each EV service tech is probably up against a stretched-thin technical support team to assist on their end... plus a learning curve all around.

Want to re-state that the service techs at this dealer were great to work with and we were in constant communication... not much else they could do better on their end. The delays seemed to come from Ford not shipping the new modules out until they got the vehicle on the lift, dropped the battery and confirmed what cell(s) needed replacing before Ford would ship the modules out. Also huge shoutout to the EV team # for their assistance in this headache... they arranged the flatbed, complicated travel (from an island), and communicated with the dealership to set up the service. For the headache that this was, everyone I spoke with was super helpful which made it a lot better of an experience.

For those interested, here are the complete service notes for the HV module repair line item, anyway:

VEHICLE ARRIVED AT DEALERSHIP ON FLAT BED, HOOKED TO FDRS, P0B24 STORED IN BECM (HV BATTERY UNSTABLE) REPROGRAMMED ALL MODULES PER RECALL 23B57, SELF TESTED BECM-P0B24 RETURNS, PERFORMED PINPOINT TEST AP, AP1-NO, AP2-YES, AP3-NO, AP4-YES - PERFORMED BATTERY HEALTH REPORT, MODULE 9 CELL 95 HILIGHTED IN BOLD AND APPEARS HIGH, CONTACTED SSSC TO OBTAIN NEW MODULE 9, HV BATTERY MODULE ARRIVE AT DEALERSHIP, PERFORMED BATTERY HEALTH REPORT AGAIN TO OBTAIN TARGET VOLTAGE CODE - FOUND CELL 95 NO LONGER HILIGHTED BUT INSTEAD HAD CELLS 45 AND 87 (MODULES 5 AND 8), RAN BATTERY HEALTH AGAIN-ONLY 87 RETURNED, CLEARED CODE AND ROAD TESTED-OK, CHARGED VEHICLE OVERNIGHT AND RETESTED IN AM-WRENCH LIGHT ON AND P0B24 STORED, BATTERY HEALTH REPORT SHOWED CELLS 95 AND 95 (MODULE 9) BOLD HILIGHT, R&R HV BATTERY AND UPON OPENING MODULE BOX SENT FROM SSSC FOUND MODULE 1 WAS SENT. WENT BACK AND FORTH WITH SSSC TO DETERMINE WHICH MODULE WAS TO BE REPLACED AND WHY IF CELLS 95 AND 95 ARE GOOD THEN WHY WERE THEY HILIGHTED-NO ANSWER. ASKED IF CELL 8 (MODULE 1) WAS THE DEFECTIVE CELL THEN WHY WASN'T THAT CELL HIGHLIGHTED-NO ANSWER, REPLACE MODULE 1 PER SSSC INSTRUCTION, BALANCED NEW MODULE, LEAK TESTED HV BATTERY, REINSTALLED HV BATTERY, CLEARED CODE, PERFORMED BECM COOLING SYSTEM FILLING AND BLEEDING-RETESTED-OK.

 

[Zprime29]

Interesting report, thanks for sharing! Definitely sounds like Ford needs to step up the support for these EV techs.

 

[dgargano]

I had posted on another thread so just copying and pasting here as well.

Alright, I have my follow-up. Picked the truck up from the dealer yesterday (33 days at the dealer).

They took care of the battery fault, the dash mat, and the rear lightbar in one visit. They had a heck of a time with the high voltage battery troubleshooting on my end. This looks like each EV service tech is probably up against a stretched-thin technical support team to assist on their end... plus a learning curve all around.

Want to re-state that the service techs at this dealer were great to work with and we were in constant communication... not much else they could do better on their end. The delays seemed to come from Ford not shipping the new modules out until they got the vehicle on the lift, dropped the battery and confirmed what cell(s) needed replacing before Ford would ship the modules out. Also huge shoutout to the EV team # for their assistance in this headache... they arranged the flatbed, complicated travel (from an island), and communicated with the dealership to set up the service. For the headache that this was, everyone I spoke with was super helpful which made it a lot better of an experience.

For those interested, here are the complete service notes for the HV module repair line item, anyway:

Very similar report as mine when they replaced module 9.

 

[massmedic]

Interesting report, thanks for sharing! Definitely sounds like Ford needs to step up the support for these EV techs.

Absolutely! This dealer in MA was great to work with, but they have only one EV tech... and it seems to be a similar case at the next two closest dealers as well. Everywhere is short the techs needed for the volume they're seeing in service departments right now, and that combined with the limited support they can get from Ford that's highlighted in that service note, I see why timelines can be stretched out so long.

Also interesting and hadn't heard this before; while talking to them, they said they have approximately 90 minutes once they crack open the battery to pull a module, place the new module and reseal the battery or else they risk losing the entire battery (something about the coolant/conditioning system, maybe?). They say their EV tech takes about 75-80 minutes alone to replace one module once opening the HV battery. If that's anywhere close to accurate, it feels like a massive gable against time for the service department to be pulling modules with one tech alone considering the cost per module or battery.

 

[Zprime29]

Also interesting and hadn't heard this before; while talking to them, they said they have approximately 90 minutes once they crack open the battery to pull a module, place the new module and reseal the battery or else they risk losing the entire battery (something about the coolant/conditioning system, maybe?). They say their EV tech takes about 75-80 minutes alone to replace one module once opening the HV battery. If that's anywhere close to accurate, it feels like a massive gable against time for the service department to be pulling modules with one tech alone considering the cost per module or battery.

Huh, first time I've heard of a time limit to swap out a battery module. Sounds very odd and surprising that Ford would design it that way. My service center misread and made some assumptions when I asked about the CSP for the software update. I wonder if yours misread something as well.

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