Charging Port Needs to be Replaced (New Truck Didn't Even Get Us Home from the Dealership)

[Mike G]

My charge port assembly had to be replaced just a couple weeks after I took delivery because the door would not open and, at a very frustrating charging stop in Quartzsite, AZ (in my mind, the worst EA station in America, and that is saying something), I literally had to pry the door off the vehicle with my fingers and a screw driver. For the next few days, I drove around with it shut with duct tape.

The somewhat good news is that my dealer - Raceway Ford in Riverside, CA - moved VERY quickly to air freight a new port assembly, in the right color, to themselves, and replaced it under warranty. I appreciated the good service. Let me add that the replaced port door continues to function six months later, tho' sometimes it takes a couple firm pushes to open.

To be clear, I LOVE my Lightning. I wish Ford's software were better and I miss passive entry, but when my long-time order for a hybrid Maverick finally arrived, I released it to the dealer in favor of keeping the Lightning.

In case you don't know...that little plastic pin that engages the locking device in the port door socket, you know, the one with the flexible silicone accordion boot on it? That pin can come off if you are cleaning in there and unintentionally turn the pin. It's a twist-lock apparently so that it can be replaced easily I guess. But if you're not careful it can fall out and get lost. And then the door would just stay open until you get a replacement.

No, I didn't lose mine. But I did get it to fall out while cleaning cobwebs out of the charging port area.

Sponsored

 

[djwildstar]

One of the things that both my wife and I agreed on during the drive home before all of the charging issues is that Ford dealers need make changes to the sales experience for EV buyers.

YES -- Your original dealer fell down on the job in many ways.

The dealer should have made sure that the truck is fully charged, clean, and ready to drive off of the lot before you arrived. Once you were there, they should have given you an introduction to the truck and its systems, and give their best shot at answering any questions you had. This is literally half of the dealership value proposition (and also company policy). If they failed to do any part of that, then they didn't do their job.

I'm guessing that the selling dealership is not on-board with Ford's EV program, doesn't particularly want you as a customer now or in the future, and was not willing to invest any time or effort on this sale. They just happened to have a Lightning on the lot, and wanted to get rid of it. I've heard of other dealers that literally just hand customers copies of the EV training materials they got from Ford.

Ford is well aware that things need to change with respect to the dealerships and EVs. They have an EV certification program for dealerships, but only about 2/3rds of Ford dealerships have signed on (you can find the EV certified dealerships using the Advanced Search option of Ford's dealer locator tool). The dealerships that aren't EV certified reportedly will not get EV retail allocations starting in 2024. Certified dealers have to put in charging infrastructure, agree to a transparent pricing policy (particularly for on-line orders), and get staff members trained up.

Even a certified dealer may not. (yet) have a DC fast charger on their lot -- so if there's a problem that allows for Level 1/2 AC charging but not DC fast charging, I can see current dealers missing it even with good prep. Certified dealers are supposed to install DC fast chargers as part of the certification program, so I'm guessing that future EV prep checklists should include testing both Level 2 and fast charging in addition to other steps.

 

[MRButtler]

Have you successfully DC charged since?

 

[Amps]

I'm guessing that the selling dealership is not on-board with Ford's EV program, doesn't particularly want you as a customer now or in the future, and was not willing to invest any time or effort on this sale. They just happened to have a Lightning on the lot, and wanted to get rid of it. I've heard of other dealers that literally just hand customers copies of the EV training materials they got from Ford.

This is why I'd like to know who the selling dealer is. I got to listen to a fair amount of EV griping and hand-wringing and even a conspiracy theory during my buying adventure.

 

[MichaelCA]

Maybe I'm different but, I dont need or want the dealer to explain to me how my truck works. I like exploring at my own leisure and probably seen enough videos on the vehicle to know more than they do.

Also a failing pin design is a FORD issue and not a dealer issue.

 

[The Weatherman]

I am a new member and first-time poster. I wish my first post was asking questions about bed coating solutions and tonneau covers, but, unfortunately, the new 2023 Ford F-150 Lightning I purchased last week didn’t even get us home. Apologies in advance for the long post (maybe it's just a rant), but I am beyond frustrated.

Last week my wife and I bought a new 2023 Lightning at a Ford dealership about 180 miles from our home. After completing the purchase on Thursday afternoon, the dealership turned the truck over to us with about 190 miles of range. I had no issue with that, and I understand that overcharging the battery can impact its service life. We planned to stop about half-way home to charge the truck to ensure we had plenty of range for the rest of the trip.

We stopped at a charging station with around 85 miles of range remaining and plugged the truck into a fast charger. The vehicle would not “connect” with the charger and the indicator next to the charging port on the truck was red. We tried several other chargers at the same location without being able to initiate a charge. We went to several other charging stations in town without being able to charge the truck on a DC charger. We also received a notification that the vehicle needed service soon and the FordPass app showed a Powertrain Malfunction. After six hours of driving from charging station to charging station and the truck almost out of range we left the truck at the local Ford dealership (not the same one we purchased from) at around midnight to make arrangements with their service department Friday morning. Given the late hour there was no public transportation available, and we ended up walking to a hotel a couple of miles away for an overnight stay we did not plan on having to make.

The following morning the dealership’s service department kindly fit us into their schedule. Later that afternoon we were told that the charging port on the truck would need to be replaced. The latest update I received suggests that they now have the part and may be able to make repairs in the next day or so. Fortunately, they arranged a rental vehicle for us without any hassle and we finally returned home Friday evening.

I understand that mechanical breakdowns on vehicles can happen anytime, but I thought my new truck would at least get me home from the dealership after I bought it. My wife, who was skeptical about the purchase anyway, is concerned that we may have gotten the proverbial “lemon.” I am a bit more optimistic about the long-term reliability of the Lightning, but am still disheartened by this experience, especially for a vehicle at this price point that is considered a flagship model for the Ford brand.

My family has almost exclusively owned Fords. This is my fourth F-150. Perhaps this will be a “bump on the road” in otherwise care-free ownership, or the beginning of a litany of issues and problems. Regardless, I have been especially frustrated this past week by the seeming lack of concern by the dealership that sold the vehicle and with the less than positive experience communicating with @Ford Motor Company customer service via chat about the issue.

Again, I apologize for the lengthy post, and I am sure my story is the exception, not the norm, for new Lightning owners. I am still excited by the truck and think it will work well for us, I just wish I could get it home.

I am genuinely sorry to see you have this kind of issue, not just early in your ownership, but at all

I bought a new 2022 this past April and I have not had the first issue and I wish everyone could have the same experience.

Good luck and welcome to the crew.

 

[VA Vikes Fan]

Kudos to Malloy!

Where did you buy it?

Yes, Malloy has been great.

Bought it at Koons Woodbridge Ford in Dale City, VA.

 

[VA Vikes Fan]

Have you successfully DC charged since?

The truck has been at Malloy Ford since last Friday. One of their techs has been working on it today. I am supposed to get an update soon as to whether I can pick it up tomorrow. At this point, I will likely wait to try DC charging at one of the stations nearer our home. Malloy has been great, but they are an hour and a half away. Worst case, if the truck needs more work I'd rather work with my local dealer (Apple Ford in Lynchburg, VA), who has been great with the endless warranty and recall service on our Ford Escape Hybrid.

 

[hturnerfamily]

I had a similar situation just yesterday: except, with a used CHEVY BOLT I bought for my son at college. We already have had two LEAFS and now even another BOLT for another son at college, so getting this BOLT was almost at no-brainer at only $17k, and with a $4 Used EX Tax Credit coming our way... 250 miles of range doesn't hurt our feelings, either...

but, on the drive home, 80 miles, it had a 'shimmy' for a second, and then the dreaded 'steering wheel shake to the death'.... all at 65 mph.
I was able to bring it to the side of the road and to a stop. I was then able to drive the rest of the way, with no issues. I alerted the dealer. Bring it in tomorrow morning. We did.

Come to find out it was a 'stuck' brake caliper, although you wouldn't know anything was amiss until the dreaded 'shake', even after driving many many miles with no issues. Thankfully, they lived up to their creed and have replaced the caliper with no issues, except more time at the dealer : /

Interestingly, after he told me that while the caliper was rather an expensive replacement that they would take care of at no charge, I reminded him of the extended MANUFACTURER'S WARRANTY on this 'GM BuyBack' vehicle may take care of this for them.
GM bought this back earlier last year from an unhappy customer, due to the nature of the 'battery issues' GM had on these Bolts for several years. Although GM would replace the battery, this former customer would not have it - they returned it back to GM. GM has provided me, the new owner of this 2017 model, with a brand new battery, a brand new battery 8 yr 1000k mile warranty, AND a 12 month MANUFACTURERS warranty on the vehicle itself.

 

[VA Vikes Fan]

Ok, so we're not quite to the happy ending stage of the story with my Lightning, but I did get good news.

Our rock star Service Advisor Glen at Malloy Ford just called me to let me know that they finished replacing the charging port and I can pick up the truck tomorrow. They don't have a Level 3 charger there, but they plugged into their Level 2 charger. I can see on the FordPass app that it is charging currently.

I won't be able to test the Level 3 charging until tomorrow, at the earliest, but as I mentioned in an earlier post, I may just wait to try that on a charger closer to home.

 

[VA Vikes Fan]

I had a similar situation just yesterday: except, with a used CHEVY BOLT I bought for my son at college. We already have had two LEAFS and now even another BOLT for another son at college, so getting this BOLT was almost at no-brainer at only $17k, and with a $4 Used EX Tax Credit coming our way... 250 miles of range doesn't hurt our feelings, either...

but, on the drive home, 80 miles, it had a 'shimmy' for a second, and then the dreaded 'steering wheel shake to the death'.... all at 65 mph.
I was able to bring it to the side of the road and to a stop. I was then able to drive the rest of the way, with no issues. I alerted the dealer. Bring it in tomorrow morning. We did.

Come to find out it was a 'stuck' brake caliper, although you wouldn't know anything was amiss until the dreaded 'shake', even after driving many many miles with no issues. Thankfully, they lived up to their creed and have replaced the caliper with no issues, except more time at the dealer : /

Interestingly, after he told me that while the caliper was rather an expensive replacement that they would take care of at no charge, I reminded him of the extended MANUFACTURER'S WARRANTY on this 'GM BuyBack' vehicle may take care of this for them.
GM bought this back earlier last year from an unhappy customer, due to the nature of the 'battery issues' GM had on these Bolts for several years. Although GM would replace the battery, this former customer would not have it - they returned it back to GM. GM has provided me, the new owner of this 2017 model, with a brand new battery, a brand new battery 8 yr 1000k mile warranty, AND a 12 month MANUFACTURERS warranty on the vehicle itself.

Your story is much more frightening than my truck not being able to charge. Glad to hear that the dealer took care of it. Also, congrats on the sweet deal on the Bolt!

 

[columbiaskier]

@VA Vikes Fan, a couple of things.

1) Your dealership is supposed to deliver the truck fully charged. Same as a gas vehicle with a full tank of gas. They did not. Why? Likely they knew of the issue.

2) If you buy a vehicle no where near home, your first stop should be the closest DC fast charger. If it doesn't work, turn around and go back. I bought one many states away, and did exactly that.

New buyers shouldn’t have to check that their vehicle works as expected before driving home.

The owner made a very reasonable assumption that the truck should charge as designed.

 

[RickLightning]

New buyers shouldn’t have to check that their vehicle works as expected before driving home.

The owner made a very reasonable assumption that the truck should charge as designed.

Guess you haven't bought any new vehicles in the last 10 years

 

[hturnerfamily]

I was actually fairly amazed that a local CHEVY dealer has not only MANY Level 2 30amp wall chargers around their dealerhsip, but also a DC FAST CHARGER(CCS)... which they find comes in handy for topping off all the CHEVY BOLTS(over 100) they have on their lot... in northeast ALABAMA, of all places... I enjoyed my son being able to fill up his 'new' 2017 BOLT we just purchased there, and I also enjoyed them allowing me to leave my LIGHTNING there, overnight, charging up on the Level 2 unit...
What's interesting, though, is that many original 'gen one' BOLTS actually did NOT necessarily come with the DC charging port pins, but ONLY for Level 2 J1772 charging... maybe not many, but it's mentioned on many as with the 'OPTIONAL' DC Fast Charging option. Interesting.

 

[columbiaskier]

Guess you haven't bought any new vehicles in the last 10 years

Haha true last two I bought from a dealer was used and had no problems. I guess I’ve been “lucky” with my new lightning

Sponsored