HV Battery Electrode Misalignment

[Scorpio3d]

I just took mine in yesterday for the ball joint recall or whatever! Luckily they checked it and everything was good. Just hope I don’t get this one!!!

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[TaxmanHog]

I'm clear ... https://www.ford.com/support/recalls/

 

[Wattsgas]

I'm a winner. Guess I better park further away from the house. I first learned about it today by CarFax email. I checked . https://www.ford.com/support/recalls/ to see if it was real, it was. But on the plus side I did get a notification from Ford that my phone as a key for Android is working. One step forward two steps back.

 

[lightspeed]

It showed up in the Ford website for me.

I assume it's going to be an entire new battery. Why would the issue be isolated to a specific module. And how could they possibly fix electrode misalignment without replacing it?

 

[GoodSam]

WINNER! By checking VIN at https://www.ford.com/support/recalls-details/

And I thot my Ford Nav problem was the big problem to get fixed with TSB 25-2048 (was SSM 52574). Plus the CSP 23B50 for the Charge Port temp via the BCCM sw; plus the Driver's Window is too sensitive when trying to close, requiring resetting by holding the switch up 15sec; and do not forget CSP 24B56 on front sensors and IPMA, which is not a problem for me yet.

Since "parts" [complete HV battery?] not available until 2nd quarter 2025, probably June, I better get these other ones taken care of in the meantime.

Where/What is a HV battery electrode and how does it get misaligned? Will they replace with a completely new set of HV battery modules or will it be a refurbished unit? Will be interesting to see what the State of Health is after replacement. I will start a @Ford Motor Company boycott if anything less than 99%.

 

[MountainAlive]

WINNER! By checking VIN at https://www.ford.com/support/recalls-details/

And I thot my Ford Nav problem was the big problem to get fixed with TSB 25-2048 (was SSM 52574). Plus the CSP 23B50 for the Charge Port temp via the BCCM sw; plus the Driver's Window is too sensitive when trying to close, requiring resetting by holding the switch up 15sec; and do not forget CSP 24B56 on front sensors and IPMA, which is not a problem for me yet.

Since "parts" [complete HV battery?] not available until 2nd quarter 2025, probably June, I better get these other ones taken care of in the meantime.

Where/What is a HV battery electrode and how does it get misaligned? Will they replace with a completely new set of HV battery modules or will it be a refurbished unit? Will be interesting to see what the State of Health is after replacement. I will start a @Ford Motor Company boycott if anything less than 99%.

My VIN looks clear. But yeah this sounds like a HV battery replacement to me, or at least a module. But who knows at this point. This tear down video from a while back may yield some clues.

 

[bmwhitetx]

I find it curious that this affects a small number of vehicles across all years (only 22-23 reported here so far). It is not limited to all vehicles made in a certain date range. My hunch is they are basing the recall on information reported from your truck.

@Old Aviator @lightspeed @GoodSam @Wattsgas - if you have the Car Scanner app can you report what your HVB Module Variation is? There are readings for both Volts and %. Based on my own experience and one other, you would like this number below ~2%.

Would be interesting to see your HVB SOH (not SOC) as well.

Another theory is that the recall is based on certain battery manufacturer dates and the way inventory worked those modules found their way in trucks across different model years (maybe late 22 to early 23??). @TaxmanHog - what percent is 940 vehicles across 22-24 total production?

 

[Grumpy2]

This certainly is confusing, the limit on 80% charge levels may have to do with swelling pouches?

From the battery teardown we see the plastic collectors at each end of the pouch. These may be the issue and be the location where swelling could short circuit where the pouch tabs are welded.
@MickeyAO commented about this connection being unique and difficult to disassemble. The plastic cracks, or deforms allowing short circuit?

The black pads used between the pouches come into play as the pouches swell and these could somehow allow too much movement from swelling?

The tear down shows numbers on each pouch, so that could explain how they can send letters to the owners of the trucks.

The weakness with my thinking: how can it effect only certain trucks spread over multiple model years? Do these parts lay on the shelf that long before use? Is each item with a serial number?

I like the theory that they monitored these specific trucks and identified the danger... but what is the danger?

Also, if it is just an issue of changing out one or two modules in a pack, why is there a shortage of parts?

 

[lightspeed]

If they know which pouch batches are bad, they can probably relate the pouches to vehicles.

My truck was made in the first or second week of 2023s after the factory restarted for MY '23 production. So the pouches affected might be for 22s and 23s around that time period (Nov 2022).

I wonder when the trucks were made for other people here with the TSB,

 

[TaxmanHog]

Why would the issue be isolated to a specific module.

They may have detailed {bar coded serial numbers} of each battery module in every truck, a few samples of failure have lead them to specific VIN's that contain these suspect parts.

 

[lightspeed]

They may have detailed {bar coded serial numbers} of each battery module in every truck, a few samples of failure have lead them to specific VIN's that contain these suspect parts.

Yeah I agree they would know what batches of pouches are bad, and where they ended up.

I'm just guessing that if batches of pouches in general go into modules in the order they are made, and that modules are put into the trucks roughly in the same order, that basically whole batteries will need to be replaced most of the time. But we'll see.

BTW I think my truck was made around the time that one truck caught fire in the shipping yard (about 4 months). So the bad batch of pouches could be from this time period and they just now getting out the tsb.

 

[TaxmanHog]

Another theory is that the recall is based on certain battery manufacturer dates and the way inventory worked those modules found their way in trucks across different model years (maybe late 22 to early 23??). @TaxmanHog - what percent is 940 vehicles across 22-24 total production?

940/70621 = 1.33%

 

[Gimme_my_MME]

https://www.f150lightningforum.com/...fect-in-the-high-voltage-battery-cells.25351/

 

[TaxmanHog]

I have data for many early 2022 / 2023 members who shared production data.
Your blend day is on your tire placard bottom center, please let us know:

@Old Aviator ?
@lightspeed ?
@GoodSam blend day was 10/12/2022
@Wattsgas blend day was 6/16/2022

Example of blend date : 06/09/2022

 

[jefrank]

I'm clear ... https://www.ford.com/support/recalls/

Ditto! whew

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