HVB high voltage battery contactor stuck and Lightning went into protect mode

[MapleMan650]

Side tracking a little here. Is anyone else experiencing an audible “click” when taking off from a standstill. Sound appears to be front driver side, my guess would be a contractor closing.

We have a thread on that sound here: https://www.f150lightningforum.com/...n-forward-or-reverse.10636/page-5#post-263953

I was able to get mine fixed by the dealer. I put the details of my visit on that thread

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[ElectrifyCLT]

This started small in the Mach E forums and turned into a massive recall (every Mach E made up till that point).

The “fix” was software. But really it was just a more graceful failure via software. Feels like Deja Vu reading this forum.

 

[sotek2345]

This started small in the Mach E forums and turned into a massive recall (every Mach E made up till that point).

The “fix” was software. But really it was just a more graceful failure via software. Feels like Deja Vu reading this forum.

Agreed. We haven't had any issues with our Mach-e yet, but it is a GT so it is just a matter of time.
If it ends up hitting the Lightning en mass like the Mach-e, it really shows a weak point in Ford's design process and thermal modeling.

 

[F-150 Prius]

Is that a service bay at a Ford dealership?

 

[HaroldCal]

Is that a service bay at a Ford dealership?

I was thinking the same thing.

 

[kwalt21]

Side tracking a little here. Is anyone else experiencing an audible “click” when taking off from a standstill. Sound

That is your CV axles. Every lightning I have driven (3) have made that noise.

Anybody cross reference the part numbers for the contactors? Does anyone know who made the contactors? Great pics btw. I find it encouraging the pack can be removed and opened easily to work on. I wonder where the pack cooling is located?

Its literally a sheet of aluminum and then adhesive is applied in a grid. Once its tacky they apply the battery module to this sheet and literally coolant runs in the grid made up of this adhesive. Crazy design.

Good question, and loaner/rental options?

They gave me the loaner lightning! Same truck as mine minus the color. (Lariat ER)

Glad it’s being resolved quickly. Any pics of the underside of the truck with the battery removed?

Unfortunately not. But Just imagine an F-150 with no drivetrain and that pretty much sums up what it looked like haha.

you have better pictures than Munro Live. Will they be replacing the battery Mounts as well?

They used the existing 8 bolts that holds the battery into the frame. They were huge!

Is that a service bay at a Ford dealership?

They have been in operation since 1956!

This is a side bay that they have for vehicles they think are going to be sitting a while waiting for parts. With the commodity issues they didn't know how long the truck would be waiting for parts. The other side of the wall is their main shop that has epoxy floors and white steel walls.

 

[kwalt21]

Thanks for sharing. Did dealer picked up the pickup? Or you used your own towing company? Was there anything tricky about getting it to the dealer?

It was picked up. Had to use the emergency tow button inside the settings screen. Other than that nothing crazy luckily. But if you don't have function of the infotainment screen you're likely SOL to get it to come out of park.

 

[metroshot]

@kwalt21 - Being in the early build year (April), makes me think it's similar to the MME HVBJB issue.

The MME had upgraded that specific part for builds after July so would the Lightnings have the similar designed part that MME had ?

Should Lightning owners with builds before July be worried ?

Has Ford made changes to the design or are they just replacing with the same part as the ones made early on ?

 

[sotek2345]

@kwalt21 - Being in the early build year (April), makes me think it's similar to the MME HVBJB issue.

The MME had upgraded that specific part for builds after July so would the Lightnings have the similar designed part that MME had ?

Should Lightning owners with builds before July be worried ?

Has Ford made changes to the design or are they just replacing with the same part as the ones made early on ?

The Lightning is a completely different battery from a different company (SKI vs LG) so it should be a different part. It also has to handle much higher current for more sustained durations (towing). The SR Lightning is close to the HP of the Mach-e GT and has more torque.

 

[Ford Motor Company]

Side tracking a little here. Is anyone else experiencing an audible “click” when taking off from a standstill. Sound appears to be front driver side, my guess would be a contractor closing.

Hi there! Would you send us a private message with your VIN and dealership name and location? I’d like to look into this concern on my end.

 

[hikinbengal]

@kwalt21 - Being in the early build year (April), makes me think it's similar to the MME HVBJB issue.

The MME had upgraded that specific part for builds after July so would the Lightnings have the similar designed part that MME had ?

Should Lightning owners with builds before July be worried ?

Has Ford made changes to the design or are they just replacing with the same part as the ones made early on ?

Mine was a September build and 3 weeks after delivery the battery already had to be dropped to get to the high voltage junction box. My fault was not as "bad" as a stuck contactor but the work is still very extensive. I doubt Ford made any modifications to their assembly line in that short of time and kept the ramp rate as high as they did.

 

[Mike G]

Side tracking a little here. Is anyone else experiencing an audible “click” when taking off from a standstill. Sound appears to be front driver side, my guess would be a contractor closing.

Nope there's a thread for that as well...it's the half-shafts. We're all waiting on the TSB. Some have had it repaired already.

 

[Citizen0]

Well this is slightly concerning. I was driving on the interstate and got a warning to pull over (I apologize for not remember the exact error). So at the next exit I pulled over and shut the truck off. Walked around it twice, got back in and all was good. I asked the dealer to check the logs while they were replacing the strut to correct my frunk problem (water intrusion, there is a thread). Received my truck in early July and really hope this doesn't happen, but at least I'm very close (5 miles) from my dealership.

Ford has been absolutely fantastic so far other than software updates, come on PAAK!)

 

[Labs4Lightning]

The Lightning is a completely different battery from a different company (SKI vs LG) so it should be a different part. It also has to handle much higher current for more sustained durations (towing). The SR Lightning is close to the HP of the Mach-e GT and has more torque.

I thought at the time of the MME recall Ford Mo Co said it was a different part in lightning

 

[Labs4Lightning]

Well this is slightly concerning. I was driving on the interstate and got a warning to pull over (I apologize for not remember the exact error). So at the next exit I pulled over and shut the truck off. Walked around it twice, got back in and all was good. I asked the dealer to check the logs while they were replacing the strut to correct my frunk problem (water intrusion, there is a thread). Received my truck in early July and really hope this doesn't happen, but at least I'm very close (5 miles) from my dealership.

Ford has been absolutely fantastic so far other than software updates, come on PAAK!)

I just scheduled service, 4 weeks for first opening, I chose 5 weeks for convenience.

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