Powertrain Malfunction/ Reduced Power

[TomB985]

So for those that got theirs repaired by no software update, what if anything have you noticed after the repair? Weird charging? Not the full battery available? Not 100% power? Anything?

Just to be clear, you’re asking about those of us who had a physical repair? Was this ever fixed with just a software update?

Mine has been perfectly normal. She’s at 100% at the moment because I’m towing the boat to the river this afternoon.

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[bmwhitetx]

So for those that got theirs repaired by no software update, what if anything have you noticed after the repair? Weird charging? Not the full battery available? Not 100% power? Anything?

I got the [faulty] PCM update after module replaced so different case. But have noticed no issues. I charged once overnight to 100% for a trip and that was 81% efficient (Wall kWh/battery kWh) instead of my typical 90-92%.

(Correction: Ratio was battery kWh/Wall kWh, not the inverse I wrote mistakenly above.)

 

[RickLightning]

Just to be clear, you’re asking about those of us who had a physical repair? Was this ever fixed with just a software update?

Mine has been perfectly normal. She’s at 100% at the moment because I’m towing the boat to the river this afternoon.

Physical repair but no PCM update.

 

[RickLightning]

I got the [faulty] PCM update after module replaced so different case. But have noticed no issues. I charged once overnight to 100% for a trip and that was 81% efficient (Wall kWh/battery kWh) instead of my typical 90-92%.

How were you measuring the amount of energy added to the battery?

I charged to 100% for a trip 2 months ago. I was at 81%, charged to 100%. Expected to 14.4kW, so with loss that would be about 15.5kW. Added 23.4kW, sending 25.44.

I was told by an expert on the Mach-E forum that when you charge to 100% there is hidden capacity used because it's the only time the charger operates in constant voltage mode.

 

[TomB985]

How were you measuring the amount of energy added to the battery?

I charged to 100% for a trip 2 months ago. I was at 81%, charged to 100%. Expected to 14.4kW, so with loss that would be about 15.5kW. Added 23.4kW, sending 25.44.

I was told by an expert on the Mach-E forum that when you charge to 100% there is hidden capacity used because it's the only time the charger operates in constant voltage mode.

81-100% means you added 19% of your truck’s capacity. 0.19•131 = 24.89 kWh, right?

 

[bmwhitetx]

How were you measuring the amount of energy added to the battery?

I charged to 100% for a trip 2 months ago. I was at 81%, charged to 100%. Expected to 14.4kW, so with loss that would be about 15.5kW. Added 23.4kW, sending 25.44.

I was told by an expert on the Mach-E forum that when you charge to 100% there is hidden capacity used because it's the only time the charger operates in constant voltage mode.

The charge session was going from 54 to 100 displayed. My math was:
Battery kWh = 131 *(100-54)% SOC = 60.26 kWh into battery
Wall kWh = 74.59 kWh from Emporia app
Charger efficiency = 60.26/74.59 = 81%

 

[RickLightning]

The charge session was going from 54 to 100 displayed. My math was:
Battery kWh = 131 *(100-54)% SOC = 60.26 kWh into battery
Wall kWh = 74.59 kWh from Emporia app
Charger efficiency = 60.26/74.59 = 81%

That was my guess. I think you experienced the same I described. About 9kWh extra.

 

[bmwhitetx]

That was my guess. I think you experienced the same I described. About 9kWh extra.

Interesting.
That same morning I drove 119 miles to an EA DCFC. 70+mph and into a strong headwind. This Trip said I got 1.7 mi/kWh. Which is ~70 kWh (119/1.7). But the charge session math (I went from 100 to 51 SOC =64.2 kWh) was 1.85 mi/kWh.

I know This Trip can be suspect sometimes, but maybe some of that extra 9 kWh came into play. Or maybe just rounding.

 

[marc_hanna]

Here is my email that I sent off to my "customer advocate" at Ford Canada:

So April, here are the events as they unfolded:

1. Took possession of my new truck on Thursday the 16th of May
2. On the 17th drove to Drumheller AB and stopped for a Level 3 charge along the way
3. Noticed fault in display with service indicator after charging
4. On the way back from Drumheller, tried to do another Level 3 charge - failed, then tried another station - failed
5. Returned to Calgary very slowly almost completely out of charge and tried to Level 3 charge again - failed
6. Did no have enough range to get anywhere
7. Called Ford roadside assistance - kept me on the line for 45 minutes and then told me they couldn’t help me until the next day
8. Found a level 2 charging station a block away and thought to give it one more go
9. Charged properly on Level 2 and got enough charge to return truck to dealership
10. Looked up fault and reported the problem to dealership on the 18th
11. Parts department at dealership looked up part and confirmed it was in stock in Ontario
12. Tuesday the 21st, Ford service technician clears code and plugs truck into Level 2 station at dealership and says the truck is fine
13. Salesman takes the truck to a Level 3 station and recreates the fault
14. Technician tells the salesman that the customer doesn’t need level 3 charging and the two get into an argument
15. Salesman goes to a second tech who accurately diagnoses the problem on Friday the 24 corresponding to my original description of the fault and orders the part.
16. The part arrives at the dealer on May 28th the first time that you make contact with me
17. Your description of the events and timeline do not align with the facts that I have
18. Repair is completed late in the day on May 29th
19. May 30th, today, I am waiting to hear back from the dealer on the success of the repair.

Now, I have to fly back to Alberta to pick up my truck and take 4 days off work to get it home in Nova Scotia or I have to pay $5,000 to have it shipped to me.

Without the help of the salesman, I don’t know where I’d be right now. He was my real customer advocate.

This is the first and last Ford I will ever buy. Both the service department and roadside assistance were complete fails. Get your act in order!

 

[TaxmanHog]

14. Technician tells the salesman that the customer doesn’t need level 3 charging and the two get into an argument

@Ford Motor Company CANADA & US, this is a real problem!
Get on it!!

 

[TomB985]

This is unfortunately a dealership problem that affects more than just Ford. I did the same dance with the service department at a Kia dealer when my mom’s EV9 ate its onboard charger. The car could use a DCFC, but would fail whenever connected to an AC charger.

The service manager was allegedly a “master EV technician.” He checked the VIN and saw there was an update available, so he applied the update and took the car outside to their wall-mounted DC charger. He said it was fixed with the software update and we could come pick it up. They had no idea that different charging methods used different components. I had to pick up the car, drive it home, shoot a video of it erroring out on the home charger, and brought it back. Six weeks later it was fixed.

 

[mb0220]

Add me to the list...
Noticed last week that power output was reduced to 57%. Charging faulted once it reached 65% SoC. Service appointment this morning, and just got word that module 6 has failed. Waiting to hear from Ford on parts availability...

 

[SmoothJ]

Add me to the list...
Noticed last week that power output was reduced to 57%. Charging faulted once it reached 65% SoC. Service appointment this morning, and just got word that module 6 has failed. Waiting to hear from Ford on parts availability...

Another 22... I hope we don't need more than one module replacement. I know I have seen others with more, but I hope thats rare.

 

[TomB985]

We know the ‘22s have these issues, but I’m really hoping to see fewer ‘23 and ‘24s. I want some confidence that Ford/SK has fixed the problem with new modules and trucks.

Oh, and I’d also like mine to not break again.

 

[marc_hanna]

We know the ‘22s have these issues, but I’m really hoping to see fewer ‘23 and ‘24s. I want some confidence that Ford/SK has fixed the problem with new modules and trucks.

Oh, and I’d also like mine to not break again.

The problem with mine was the DC charging module. It's a '23

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