Powertrain Malfunction/ Reduced Power

[massmedic]

Huh, first time I've heard of a time limit to swap out a battery module. Sounds very odd and surprising that Ford would design it that way. My service center misread and made some assumptions when I asked about the CSP for the software update. I wonder if yours misread something as well.

Yes, I thought the same, hadn't heard anything about that before and sounded weird but I was tired and didn't try to get more info at the time. I almost wonder if maybe they misspoke and it's a time limit before additional service would have to be done to the entire pack or something instead, because I can't wrap my head around there being a time limit that short for something that expensive and complex.

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[TaxmanHog]

Absolutely! This dealer in MA was great to work with, but they have only one EV tech... and it seems to be a similar case at the next two closest dealers as well.

Positive experiences are worthy of notoriety, which dealer is this?

 

[LazyLightningATX]

Yay! Picked up the truck today. Everything seems good. They replaced module no. 8 due to cell 80 showing low voltage. $11k parts cost and $6k labor (13 hours) is what the invoice shows!!! Truck was there from 11/18-12/7. Glad I’m not on the hook for that! Hopefully this is the last I have to deal with this. Now, about those software updates…?

 

[MickeyAO]

Also interesting and hadn't heard this before; while talking to them, they said they have approximately 90 minutes once they crack open the battery to pull a module, place the new module and reseal the battery or else they risk losing the entire battery (something about the coolant/conditioning system, maybe?). They say their EV tech takes about 75-80 minutes alone to replace one module once opening the HV battery. If that's anywhere close to accurate, it feels like a massive gable against time for the service department to be pulling modules with one tech alone considering the cost per module or battery.

After tearing down numerus battery packs, I find this hard to believe. They imply that normal air will contaminate the coolant, but you add the coolant through a reservoir that opens to normal air. Or maybe they think the seals will deteriorate when exposed to air? I have never seen anything break down when we open a pack. Heck, the MachE pack has been left open for several months and all the seals we didn't disconnect are still in good shape.

More likely, Ford says that it should only take 90 minutes to replace the module.

 

[massmedic]

Positive experiences are worthy of notoriety, which dealer is this?

Ah, yes - Balise Ford in Hyannis MA. Bit of a hike, but have enjoyed dealing with them.

After tearing down numerus battery packs, I find this hard to believe. They imply that normal air will contaminate the coolant, but you add the coolant through a reservoir that opens to normal air. Or maybe they think the seals will deteriorate when exposed to air? I have never seen anything break down when we open a pack. Heck, the MachE pack has been left open for several months and all the seals we didn't disconnect are still in good shape.

More likely, Ford says that it should only take 90 minutes to replace the module.

It did sound odd at the time... it was the service manager/rep that said this and not the EV tech, so purely out of curiosity I may give them a call tomorrow and see if he can explain that to me again. But he did elaborate a little at the time and said that because of the 90 minute limit, it was important that the EV tech wasn't interrupted and could focus, so that made it sound like it wasn't a billable problem where he could pause/resume as needed to bill for the time...

 

[Avocadodude]

Yay! Picked up the truck today. Everything seems good. They replaced module no. 8 due to cell 80 showing low voltage. $11k parts cost and $6k labor (13 hours) is what the invoice shows!!! Truck was there from 11/18-12/7. Glad I’m not on the hook for that! Hopefully this is the last I have to deal with this. Now, about those software updates…?

Having been there multiple times, always happy to see a truck go home

 

[LazyLightningATX]

Having been there multiple times, always happy to see a truck go home

Really hope I don't have to go through that again! Charged it up to 90 overnight. Everything looks good. Just finished first drive back to work and I had almost forgotten how awesomely smooth and quiet the Lightning is! Especially compared to the garbage xlt ecoboost they had me in. Transmission in that thing is really awful.

 

[Zprime29]

$11k parts cost and $6k labor (13 hours) is what the invoice shows!!!

$11k for one module? Might be just me, but that seems excessive. Glad you have your truck back and didn't have to foot that bill.

 

[hturnerfamily]

I imagine there are 'retail' prices, and then there are REAL prices, as for warranty work. It's like in the healthcare business: a hosptial can charge you ANY fees or pricing they wish, regardless of how 'ridiculous' it may be, but the INSURER, or Medicare, will NEVER pay such a price - they will pay what the 'agreed' pricing is, or, in the case of Commercial Insurers, the 'normal and acceptable' pricing.

Why Ford would show any specific 'amount' is probably only for accounting purposes.

 

[MAFleetLightning]

Second battery has arrived to dealer. It took half the time to get there compared to the first battery. Can't be worked on until Monday at the earliest as the tech that is trained to do the work is out until Monday..... Monday make a month at the dealer.

@Ford Motor Company This is clearly a somewhat large issue. Ford should proactively be stocking replacement batteries and other parts at the dealerships and get more techs trained on the issues.

Do other EVs have these problems? This is why the general public is losing faith in EVs. If the truck works fine its amazing, waiting for weeks at a time for repairs is going to make people hesitant to get rid of their ICE vehicles.

Lack of updating on my end. Got the truck back after having modules 2 and 7 replaced which took a total of 5 weeks, mainly waiting for the batteries. I've put almost 1000 miles on and no issues (fingers crossed). Takeaways - 1. The remaining 7 modules on my truck could have issues down the road. 2. Dealers need more EV trained technicians, the dealership hates working on EVs, they said as much to me. 3. Ford needs to send batteries to dealers to have in stock. THIS IS A KNOWN PROBLEM, they say 4% of trucks are affected, seems potentially higher than that. Truck is amazing when it works, but 5 weeks on the shelf is simply not acceptable. @Ford Motor Company

 

[Pete22569]

Dealer has to replace the battery HV Module 4. They ordered the part a week ago and still have no eta.

I did find an interesting video someone else posted that shows what work is involve. I hope they test every module before buttoning it back up.

 

[dgargano]

Dealer has to replace the battery HV Module 4. They ordered the part a week ago and still have no eta.

I did find an interesting video someone else posted that shows what work is involve. I hope they test every module before buttoning it back up.

Thank you. Very informative. I knew it wasn't easy to get to the batteries. This is larger job than I thought.

 

[Yankee_foxttot]

Funny that I joined the forum today JUST to report the problem.

I was driving my kids to swim class yesterday and it stopped on the middle of the road..

same exact error message.

 

[Pro or NO]

eek, crossing my fingers for you

Found out this morning I got lucky. Just a coolant temp sensor that acted up a few days and then was normal. Sensor is being replaced anyway. Trucks been fine.

 

[Dolio]

Just wanted to add: https://www.f150lightningforum.com/...ing-build-week-group-my2023.12470/post-355955 where I have had module #6 replaced and am currently in the middle of having Module #2 replaced.

I am curious, which build week group the truck with bad modules belong to, Am curious is the battery module batch is related. As I recall, mine was being build around the time that they had that week long delivery stoppage related to them catching a battery issue...

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