2023 battery updates discovered in service manual

[MountainAlive]

So I decided to buy a service manual for the Lightning from factory-manuals.com and I'll say it's pretty comprehensive. They ask for your VIN and it's embedded in the file so I'm not at liberty to share any parts of it. However, when I was looking at the procedure to replace a high voltage battery module, I saw something that caught my attention that I hadn't seen reported in this forum yet.

Apparently in late 2023 they made a couple updates to the battery. On one of the pages it noted:

NOTE: High voltage battery trays built from 11-August-2023 are equipped with vent valves on the high voltage battery tray.
NOTE: High voltage battery trays built from 09-June-2023 are equipped with heat shields under the cold plates.
The vent valves are located at the back of the battery pack and there are four of them. I can't tell if this is a replacement for the side vent or in addition to that. But still, it's at least interesting. I wonder what the pros/cons are of this update.

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[TaxmanHog]

Only a guess, but in the rare event of a full blown thermal breakdown, they want the hot gasses / flames to exit the rear so that passengers are less likely to be harmed while exiting the truck cabin.

Vent location on the 2022 pack

 

[Ish]

Here’s the page from Ford’s 2023 Body Builders Layout Book. It looks like they’re at or immediately rear of the B pillar and it states there can be no modifications within 150 mm of the vents.

 

[MountainAlive]

Only a guess, but in the rare event of a full blown thermal breakdown, they want the hot gasses / flames to exit the rear so that passengers are less likely to be harmed while exiting the truck cabin.

Vent location on the 2022 pack

That might be the reason behind the change. Here's a picture of the late 2023 vent valves in the back of the battery pack. I do wonder if water intrusion is a concern with any of these vents but it seems they are one-way to relieve internal pressure.

 

[invertedspear]

So I decided to buy a service manual for the Lightning from factory-manuals.com and I'll say it's pretty comprehensive. They ask for your VIN and it's embedded in the file so I'm not at liberty to share any parts of it. However, when I was looking at the procedure to replace a high voltage battery module, I saw something that caught my attention that I hadn't seen reported in this forum yet. Apparently in late 2023 they made a couple updates to the battery. On one of the pages it noted:
NOTE: High voltage battery trays built from 11-August-2023 are equipped with vent valves on the high voltage battery tray.
NOTE: High voltage battery trays built from 09-June-2023 are equipped with heat shields under the cold plates.
The vent valves are located at the back of the battery pack and there are four of them. I can't tell if this is a replacement for the side vent or in addition to that. But still, it's at least interesting. I wonder what the pros/cons are of this update.

This might finally explain why my early August 2023 build didn’t get to the dealer till the very end of October.

 

[chl]

EV battery vents are definitely a safety feature as well as being part of the thermal management system to avoid battery damage/failure and to try to keep the Li EV battery within its ideal temperature range (20-30 degrees C or 68 to 86 degrees F) for best performance and longevity.

Some basic info about the function of an EV battery vent:

What is an EV battery vent?
An EV battery vent is a safety feature integrated into the design of battery packs used in EVs. Its primary function is to manage and release gases generated within the battery cells, particularly under abnormal conditions such as overcharging, overheating, or short-circuiting. These vents prevent the build-up of excessive pressure inside the battery, which could otherwise lead to dangerous scenarios, including explosions or fires.

How does an EV battery vent work?
During regular operation, the battery vent remains sealed, maintaining the integrity and pressure of the battery pack. This ensures that the battery operates efficiently and safely under standard conditions.

When a battery cell undergoes stress due to overcharging, internal short circuits, or thermal runaway (an uncontrolled increase in temperature), chemical reactions can produce gases. Various factors, such as the battery type and capacity influence the required amount of ventilation for batteries. As these gases accumulate, the battery's internal pressure rises. When the pressure exceeds specific safe limits, the EV battery vent opens to release the built-up gases. This controlled release prevents the battery casing from rupturing and mitigates the risk of fire or explosion.

Importance of EV battery vents
EV battery vents are not just about safety. They also play a crucial role in thermal management, preventing overheating and thereby extending the life of the battery. This added durability is a key factor in the reliability of EVs. Additionally, these vents are mandated by many safety standards and regulations, making them essential for market compliance.

From: https://www.batterytechonline.com/ev-batteries/understanding-ev-battery-vents

See also: "An Overview of EV Lithium-ion Battery Heating and Cooling Technology: air/liquid/refrigerant cooling" at for a comparison of thermal systems (air, liquid and liquid immersion), although vents are not mentioned.

And see "Cooling 50,000 Degrees... Lightning Thermal System Breakdown" at for details about the Lightning thermal management system.

 

[MountainAlive]

EV battery vents are definitely a safety feature as well as being part of the thermal management system to avoid battery damage/failure and to try to keep the Li EV battery within its ideal temperature range (20-30 degrees C or 68 to 86 degrees F) for best performance and longevity.

Some basic info about the function of an EV battery vent:

What is an EV battery vent?
An EV battery vent is a safety feature integrated into the design of battery packs used in EVs. Its primary function is to manage and release gases generated within the battery cells, particularly under abnormal conditions such as overcharging, overheating, or short-circuiting. These vents prevent the build-up of excessive pressure inside the battery, which could otherwise lead to dangerous scenarios, including explosions or fires.

How does an EV battery vent work?
During regular operation, the battery vent remains sealed, maintaining the integrity and pressure of the battery pack. This ensures that the battery operates efficiently and safely under standard conditions.

When a battery cell undergoes stress due to overcharging, internal short circuits, or thermal runaway (an uncontrolled increase in temperature), chemical reactions can produce gases. Various factors, such as the battery type and capacity influence the required amount of ventilation for batteries. As these gases accumulate, the battery's internal pressure rises. When the pressure exceeds specific safe limits, the EV battery vent opens to release the built-up gases. This controlled release prevents the battery casing from rupturing and mitigates the risk of fire or explosion.

Importance of EV battery vents
EV battery vents are not just about safety. They also play a crucial role in thermal management, preventing overheating and thereby extending the life of the battery. This added durability is a key factor in the reliability of EVs. Additionally, these vents are mandated by many safety standards and regulations, making them essential for market compliance.

From: https://www.batterytechonline.com/ev-batteries/understanding-ev-battery-vents

See also: "An Overview of EV Lithium-ion Battery Heating and Cooling Technology: air/liquid/refrigerant cooling" at for a comparison of thermal systems (air, liquid and liquid immersion), although vents are not mentioned.

And see "Cooling 50,000 Degrees... Lightning Thermal System Breakdown" at for details about the Lightning thermal management system.

I’ll check out these videos thanks. Do you know if someone were to tread deep water higher than these vents if that would cause water intrusion? Or are the vents one-way?

 

[chl]

I’ll check out these videos thanks. Do you know if someone were to tread deep water higher than these vents if that would cause water intrusion? Or are the vents one-way?

I've wondered about that myself and trust they one way.

One of the explanations I read says: "...When the pressure exceeds specific safe limits, the EV battery vent opens to release the built-up gases. This controlled release prevents the battery casing from rupturing and mitigates the risk of fire or explosion...."

So sounds like one-way to me.

Water getting into the Li Battery innards (a technical term) would be a disaster.

Miss AI know-it-all says:


"...Electric vehicles (EVs) have several features to keep water out of their batteries, including:

Sealed battery packs
EVs have sealed battery packs that are usually waterproof to some degree.



Moisture management systems
These systems use pressure valves and diaphragms to balance pressure inside the battery housing and prevent moisture from getting in.


Insulation barriers
Insulation barriers separate different cells in the battery pack to help keep moisture out.


Weatherproof charging components
Charging components are sealed and weatherproof to prevent rainwater from interfering with the charging process.


Safety precautions
Before charging, the charger communicates with the EV to ensure conditions are safe.

However, if water does get into the battery, it can cause short circuits, damage the battery cells, and reduce performance. Submerging an EV in standing water can also overcome the moisture seals in the battery and potentially cause a fire...."

 

[chl]

This one would worry me "Submerging an EV in standing water can also overcome the moisture seals in the battery and potentially cause a fire..."

https://www.gtcounty.org/CivicAlerts.aspx?AID=473

 

[subseavet]

I’ll check out these videos thanks. Do you know if someone were to tread deep water higher than these vents if that would cause water intrusion? Or are the vents one-way?

I have to imagine these are gas blow out disc's. Normally totally sealed. Once pressure exceeds a set limit inside the sealed pack the seals blow out/pop releasing pressure in a controlled manner. Once they do, they will not be water or air tight but in that scenario, you likely don't care anymore. But if they aren't above that pressure they are as tight as any other part of the system. We use these style blow out discs and vents on undersea batteries and motors all the time. They work really well and are very much water tight and one way in nature unless you exceed the disc pressure.

 

[Mike G]

I have to imagine these are gas blow out disc's. Normally totally sealed. Once pressure exceeds a set limit inside the sealed pack the seals blow out/pop releasing pressure in a controlled manner. Once they do, they will not be water or air tight but in that scenario, you likely don't care anymore. But if they aren't above that pressure they are as tight as any other part of the system. We use these style blow out discs and vents on undersea batteries and motors all the time. They work really well and are very much water tight and one way in nature unless you exceed the disc pressure.

They are vent valves.

When the pack is tested the pressure is set on the "VACUTEC® Smoke Machine Fuel EVAP Emissions System Tester" to <0.5psi. That's enough to conduct the test but not enough to cause venting.

Additionally, bandages (seriously they're bandaids) are placed over each of the vents and then those are covered with clear packing tape.

Special Tool(s) / General Equipment

• VACUTEC® Smoke Machine Fuel EVAP Emissions System Tester (or equivalent)
• SNOOP Solution
• Large Adhesive Bandage
• Tape
• Shop Air Supply
• 1 1/2" (38mm) QWIK Caps

 

[ciferguson37733]

So I decided to buy a service manual for the Lightning from factory-manuals.com and I'll say it's pretty comprehensive. They ask for your VIN and it's embedded in the file so I'm not at liberty to share any parts of it. However, when I was looking at the procedure to replace a high voltage battery module, I saw something that caught my attention that I hadn't seen reported in this forum yet.

Apparently in late 2023 they made a couple updates to the battery. On one of the pages it noted:

NOTE: High voltage battery trays built from 11-August-2023 are equipped with vent valves on the high voltage battery tray.
NOTE: High voltage battery trays built from 09-June-2023 are equipped with heat shields under the cold plates.
The vent valves are located at the back of the battery pack and there are four of them. I can't tell if this is a replacement for the side vent or in addition to that. But still, it's at least interesting. I wonder what the pros/cons are of this update.

I’m interested in this manual. The web site lists the F150 but does not call out the Lightning specifically. Or am I missing it?

it does call out the Mach e specifically.

 

[RaspPiDude]

Is the service manual a good buy for folks who want to tinker and upgrade parts here and there? I've never seen what's inside one, but I assume it's an exploded view of every part of the vehicle to aid in maintenance and repairs?

 

[MountainAlive]

I’ve only just started poking around with it. It was around $60-70 I think so I figured what the heck, I’ll try this. To someone’s earlier question, this covers the F150 Lightning specifically because when you purchase, they ask for your VIN which indicates you have a BEV. So the manual is built accordingly. The PDF they gave me was over 2 GB in size so it is full of tons of info. However, I’m just a DIY person who has historically worked on his own vehicles, so that’s my main reason for exploring this. This is my first EV so I have so much to learn.

 

[Hammick]

I’ve only just started poking around with it. It was around $60-70 I think so I figured what the heck, I’ll try this. To someone’s earlier question, this covers the F150 Lightning specifically because when you purchase, they ask for your VIN which indicates you have a BEV. So the manual is built accordingly. The PDF they gave me was over 2 GB in size so it is full of tons of info. However, I’m just a DIY person who has historically worked on his own vehicles, so that’s my main reason for exploring this. This is my first EV so I have so much to learn.

You mind posting a link where we can purchase it?

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