Safety Program: 25S18: HV Battery Electrode Misalignment Discussion

[GoodSam]

@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.

WINNER: SR pack, Build Date Oct,2022, variation recently seen 0.33%, HVB SOH was 99%, 15K miles.

Sponsored

 

[Maxx]

how can it effect only certain trucks spread over multiple model years?

Larry here worked on 940 packs and right before he was fired for doing drugs on the job, he told his boss you will pay for this.

 

[Albern]

I just checked my VIN on my Ford Account and on the Ford Support page, which didn't turn up anything. Are these sources up-to-date as of right now?

I'm in Canada and my build was in February 2024.

 

[TaxmanHog]

My truck's production date is 4/22 and the blend date is 4/6/22. I read that production began 4/26/22, so mine is very early. It was a dealer "mannequin" demo. I wonder what position mine was along the assembly line. I've heard the the last digits of a VIN aren't necessarily sequential for vehicles going down the line. At any rate, it was made in the first four days of regular production.

My truck is not part of the recall.

The vin sequence numbers bare NO relationship to sequence of manufacture on a day by day minute by minute basis. They're assigned when your truck is accepted for production early in the scheduling process.

My goal is to hear POSITIVE indications from affected members, with your blend dates, then we will have an approximate span build dates impacted, we know it's 940 trucks, is that 100% of truck spread out along a narrow time frame or a much lower percentage along a wider time frame

 

[lightspeed]

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

Mine says 10/22

 

[TaxmanHog]

There were 19,209 Lightnings built during the weeks 4/4/2022 to 10/31/2022 (covers MY 22 & 23 transition), 940 / 19,209 = 4.89%

 

[GoodSam]

There were 19,209 Lightnings built during the weeks 4/4/2022 to 10/31/2022 (covers MY 22 & 23 transition), 940 / 19,209 = 4.89%

Ford is saying certain 2022-2024. SP 25S18, so your other estimate of 940/70621 = 1.33% might be closer?
https://www.f150lightningforum.com/forum/threads/safety-program-25s18-certain-2022-2024-f-150-lightning-–-supplier-manufacturing-defect-in-high-voltage-battery-cells.25351/

How do they know which ones to recall? Factory info or can they determine remotely after looking at our trucks' info?
I wonder if this just a delayed response to the February, 2023? battery fire in their storage lot, and they finally determined it was worth their while to avoid lawsuits, and charge it to their supplier SK On, to recall HV batteries of a certain production run of modules that could expand a bit too far when fully charged (limiting us to 80%), which would disengage one +/- electrode end of a group of pouches that make up a cell and short to ground, causing burn through to other cells, fire etc. I guess that could even happen if a fuse was in line somewhere - it could not prevent the chemical burn from continuing.
Interesting that a bad module made, say, from 2022 to 2023, could possibly get into a 2024 model. I would think that HV battery modules would be first in, first out, and not be hanging around very long in production.

 

[TaxmanHog]

Ford is saying certain 2022-2024. SP 25S18, so your other estimate of 1% might be closer?
https://www.f150lightningforum.com/forum/threads/safety-program-25s18-certain-2022-2024-f-150-lightning-–-supplier-manufacturing-defect-in-high-voltage-battery-cells.25351/

I'll adjust the percentage as more members chime in to extend the start & end dates of my current readout, unfortunately my measurements of production in MY 24 is incomplete.

 

[GoodSam]

I'll adjust the percentage as more members chime in to extend the start & end dates of my current readout, unfortunately my measurements of production in MY 24 is incomplete.

I think @Ford Motor Company is just messing with us...they need a tax write-off of $40,000,000 which is 940 vehicles x $42,553.19 each (9 modules x $4K + labor)!

 

[lightning-spark]

https://static.nhtsa.gov/odi/rcl/2025/RCMN-25V131-0013.pdf

This appears to be the vehicles affected:

2022 Model Year - March 16, 2022 through October 19, 2022

2023 Model Year - October 20, 2022 through November 20, 2023

2024 Model Year - December 19, 2023 through August 14, 2024

 

[SmoothJ]

Looks like I am clear, even though my truck was built in June 2022.

 

[TaxmanHog]

https://static.nhtsa.gov/odi/rcl/2025/RCMN-25V131-0013.pdf

This appears to be the vehicles affected:

2022 Model Year - March 16, 2022 through October 19, 2022

2023 Model Year - October 20, 2022 through November 20, 2023

2024 Model Year - December 19, 2023 through August 14, 2024

That would be the entirety of production for all three model years ~122,799 trucks so 0.765% {0.00765} are the 940 or so affected

 

[jetfixr1]

That would be the entirety of production for all three model years ~122,799 trucks so 0.765% {0.00765} are the 940 or so affected

Wonder what pattern they found to affect such a small population of trucks? Maybe an untrained assembly technician or QA person?

 

[TaxmanHog]

Wonder what pattern they found to affect such a small population of trucks? Maybe an untrained assembly technician or QA person?

I think it's an isolated machine (one of many) that was not set up correctly assembling the pouch cells into groups within an array, that or it was initially set up correctly then fell out of tolerance and no one detected the marginal flaw. {my pure speculation}

 

[ddbrooke]

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 build month 4/xx/2022
@lightspeed build month 10/xx/2022
@GoodSam blend day was 10/12/2022
@Wattsgas blend day was 6/16/2022

Example of blend date : 06/09/2022

My blend date for my 2022 is 08/22 however my Ford account doesn't show a recall notice. Hopefully that means I'm in the clear