Front light bar partially lit

[Dinozero]

Stuff like this is why I am keeping my Ford ESP even tho HVB are not covered.

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[toehlke84]

My passenger side is also half lit and just out of warranty. Ford Premier Care refused coverage and diagnosis was going to be $200-300, parts another $300 + labor. Headlamp assembly (which thankfully still works) is $1000 to replace. I'm going to leave it half lit and try to disable the other side to match. I don't like the light bar anyway. Personally, I wish the truck looked identical to gas f150 and would love to rip all the Lightning badging off it.

 

[Maquis]

My passenger side is also half lit and just out of warranty. Ford Premier Care refused coverage and diagnosis was going to be $200-300, parts another $300 + labor. Headlamp assembly (which thankfully still works) is $1000 to replace. I'm going to leave it half lit and try to disable the other side to match. I don't like the light bar anyway. Personally, I wish the truck looked identical to gas f150 and would love to rip all the Lightning badging off it.

Lamp coverage is (was) a $70 adder to Premium Care plans.

 

[Randall Stephens]

Lamp coverage is (was) a $70 adder to Premium Care plans.

I felt the only reason to get the premium coverage was the ability to add the cheap LED coverage. I feel like the move to LEDs has been a step backwards for us folks th at hold onto these things for decades. It’s part of the push to not allow you to fix your own shit.

 

[RI fisherman]

Lamp coverage is (was) a $70 adder to Premium Care plans.

i have the same problem and had it in the shop last week, i refused to pay what they wanted to diagnose so took it apart to see what it could be .and this is what i find on the connector! not happy.

 

[RI fisherman]

two of the pins corroded all the way off! we need a recall to fix this

 

[RI fisherman]

Meant to write this before i posted the pictures. Well color me officially Annoyed... had my truck in for some recent recalls so i asked the service manager if they could diagnose why the front light bar is half out. the said since it outside Bumper to bumper 44K miles i would have 2 pay 175 buck fee for diagnostic and they might need it for 2 days as the tech's need to get into all the panels and such... dropped the truck off Friday they had Saturday and Monday no calls, so i followed up. still said they needed it for recalls. Ford letter said 1/2Day work? Monday night Service manger calls back, apologizes said do i really need them to look at the light bar, its gonna be at least 5/6 hours of work, to figure it out and if its not deemed to be under warranty you will have to pay, so I said at this point no, since i was paying out of pocket for loaner. 50$ day. he said they could finish recall work tomorrow, which they did and i picked up Thursday night. He was nice enough enough to comp 2 days of rental since he agreed it shouldn't have taken that long and they had the parts. but no luck with light bar.

Fast forward to today. I decided to take e a look at myself. I pulled the trim and front grill all of 20 mins work. (thanks for the detailed write up @@shoopg) and when I pulled of the light bar electrical connectors plugs I see the tell tale signs of Green death on the electrical pins. and then the main plug is so corroded that one of the pins has completely corroded away!!! there is minimal waterproofing IMO on the connectors themselves but still this shouldn't not look like this on a 2 year old truck. there was lots of moisture behind the grill as it had rained the morning I decided to do this so to me there is a major design flaw and I'm guessing will be happening to many of us unless ford changed the design / location of these connectors.

What do we think this should should be covered under electrical warranty for BEV? or should ford consider this for recall. I really don't think i should have to pay to have this fixed. also if anyone knows the part number for the harness itself let me know as i cant find yet...

 

[toehlke84]

Meant to write this before i posted the pictures. Well color me officially Annoyed... had my truck in for some recent recalls so i asked the service manager if they could diagnose why the front light bar is half out. the said since it outside Bumper to bumper 44K miles i would have 2 pay 175 buck fee for diagnostic and they might need it for 2 days as the tech's need to get into all the panels and such... dropped the truck off Friday they had Saturday and Monday no calls, so i followed up. still said they needed it for recalls. Ford letter said 1/2Day work? Monday night Service manger calls back, apologizes said do i really need them to look at the light bar, its gonna be at least 5/6 hours of work, to figure it out and if its not deemed to be under warranty you will have to pay, so I said at this point no, since i was paying out of pocket for loaner. 50$ day. he said they could finish recall work tomorrow, which they did and i picked up Thursday night. He was nice enough enough to comp 2 days of rental since he agreed it shouldn't have taken that long and they had the parts. but no luck with light bar.

Fast forward to today. I decided to take e a look at myself. I pulled the trim and front grill all of 20 mins work. (thanks for the detailed write up @@shoopg) and when I pulled of the light bar electrical connectors plugs I see the tell tale signs of Green death on the electrical pins. and then the main plug is so corroded that one of the pins has completely corroded away!!! there is minimal waterproofing IMO on the connectors themselves but still this shouldn't not look like this on a 2 year old truck. there was lots of moisture behind the grill as it had rained the morning I decided to do this so to me there is a major design flaw and I'm guessing will be happening to many of us unless ford changed the design / location of these connectors.

What do we think this should should be covered under electrical warranty for BEV? or should ford consider this for recall. I really don't think i should have to pay to have this fixed. also if anyone knows the part number for the harness itself let me know as i cant find yet...

Did you ever get resolution or warranty coverage on that? I'm having same issue and have an appt scheduled for next Tuesday.

 

[toehlke84]

two of the pins corroded all the way off! we need a recall to fix this

Same with me.

 

[RI fisherman]

Same with me.

Negative no resolution yet still have a case open though I haven't heard anything new in a couple weeks. So not holding my breath

 

[VTbuckeye]

My power tailgate stopped working at the end of last winter. They fixed it.... Corroded connector. Electrical connections that are exposed to weather/environment need to be water tight. They have been building vehicles for a long time. They should know how to not screw this up.

 

[XENOILPHOBE]

Lets hope they did a better job with water tight connection on the traction high voltage battery or we are going to see nasty arcing in the future... Maybe this is how the Lightning Flash earns its name?

Have any of you smelled melting plastic or an electrical ozone like smell? I have noted this smell in the frunk whenever it rains a lot. this might be what I am smelling. I freaking hope not, I am going to pull the plugs and inspect and run a FLIR over the plugs in the frunk and the tailgate.. This truck is an April 2024, it shouldn't have issues, but those plugs in the 2022's above are totally compromised by water ingress... that green oxidation is a dead giveaway. You can clean it off with vinegar and baking soda, but the damage is already done... If they wont cover it, I would just hard wire it and heat shrink the connections, but this shouldn't be happening on a truck that has been built by a company building trucks since 1903.

Aren't the traction high voltage batteries 480 volts? Maybe the should have named the Lightning the ARC Flash, now the Lightning Flash is starting to make sense...

Maybe they need to call Tesla - https://www.tesla.com/blog/standardizing-automotive-connectivity

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