Powertrain Malfunction/ Reduced Power

[TaxmanHog]

I believe there are 4 variants between ER & SR and the Large & Small modules, shelving these four units is 20k in shelf inventory. Maybe stockpile them at regional distribution centers so they can shave a day+ off transit time?

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[Piquette]

I picked up my Lightning this afternoon from Grappone Ford in Concord, NH, after having battery module #7 replaced. Those people are terrific. I had dropped it off with them on December 26. Most of the intervening time was spent waiting for Ford to ship the replacement for Module 7. The replacement module arrived last Friday, and the service technician started installing it yesterday (Monday) morning. He had the new module installed by the end of the day, and performed software updates on all related modules, checked the coolant levels, and charged the battery to 85% overnight. This morning they let me know it was ready, so I picked it up and drove it home. Everything performed as it should.

I spent some time with the service technician and learned some things. First, Taxmanhog is correct, there are only four different battery modules used on SR and ER Lightnings. Both SR and ER batteries use 9 battery modules. SR modules are different from ER modules and can’t be interchanged with ER modules. Modules 1 through 8 are identical and can be interchanged with any other module from 1 through 8. Module 9, which is located at the front of the battery, is different from the other 8 modules and cannot be interchange with a module from 1 through 8. So there are a total of 4 different modules used in Lightning batteries, 2 different ones in SR batteries, and two other different ones used in ER batteries..

The other thing I learned is that new replacement modules are shipped about 50% charged. If the truck arrived with its modules more than 50% charged, the state of charge of those modules has to be brought down to 50% to match the new one before the new module can be installed and the battery software can be updated. If the other modules are below 50% charged, the new module has to be brought down to match the others.

If you do have a cell failure that requires replacing a battery module, park the truck immediately to conserve the charge in the battery until it can be serviced. The service technician told me that it is much easier to update the module software if there is close to 50% charge in the remaining battery modules. One Lightning came in with only 14% charge left in the battery, and the technician said it was quite a bit more work to update all the module software because of that.

This was the second time a battery module has had to be replaced on my truck. Module 9 had to be replaced last February. This time it was module 7. Unfortunately, there is no way to determine if or when a module is going to fail. Hopefully the remaining 7 original modules will be good for the life of my truck, but only time will tell.

 

[TaxmanHog]

I picked up my Lightning this afternoon from Grappone Ford in Concord, NH, after having battery module #7 replaced. Those people are terrific.

Thanks for the detailed update and reporting that Grappone continues with its stellar service, I'm also hopeful the remaining life of your Lightning is more reliable.

 

[Mwillselectric]

Great update, thanks for all that info! Irwin still has mine, they received the battery but didn’t order the adhesive to attach the batteries to the cooling plate, so now I’m apparently waiting on that, which they said will be another week, after the owner assured me I would get my truck back today. So I will take your advice and go to Grapppne moving forward, my experience with this dealer has been the worst customer service experience I have ever dealt with, for anything.

 

[vvgogh]

...two other different ones used in ER batteries.

This makes it even more frustrating. There's only two module form factors for my truck. Why can't the service department keep the two modules on hand? Ford delays an already lengthy repair process by two more business days. Let the service department order the replacement module and get it shipped quickly. I bet the payment term is NET10 or longer, so there's no reason for a two day Ford approval delay to order a part.

@Ford Motor Company - This is a bad experience. You can make it better with process improvements. Let the service department stock the needed parts for speedy repairs. Don't delay shipping with red tape.

 

[TaxmanHog]

This makes it even more frustrating. There's only two module form factors for my truck. Why can't the service department keep the two modules on hand? Ford delays an already lengthy repair process by two more business days. Let the service department order the replacement module and get it shipped quickly. I bet the payment term is NET10 or longer, so there's no reason for a two day Ford approval delay to order a part.

@Ford Motor Company - This is a bad experience. You can make it better with process improvements. Let the service department stock the needed parts for speedy repairs. Don't delay shipping with red tape.

Between US & Canada there are about 3200 dealerships.

To hold stock for both a SR & ER truck, it's 4 modules to be ready for either powertrain failure rolling into the shop, $64 million dollars for parts on standby, that is extremely expensive and wasteful!!

I'd be happy to have regional parts depot's located a days drive by freight to any dealership have a number of each version SRx2 and ERx2 factored based on potential service burden in the region (number of trucks registered), then let the depot resupply accordingly from the battery assembly plant.

 

[Gimme_my_MME]

I'd be happy to have regional parts depot's located a days drive by freight to any dealership have a number of each version SRx2 and ERx2 factored based on potential service burden in the region (number of trucks registered), then let the depot resupply accordingly from the battery assembly plant

That is what is done. There were extenuating circumstances that caused the recent delays

 

[vvgogh]

The HVB is staying disconnected until the new module arrives. Is that going to cause the low voltage battery to discharge and damage itself in the next week?

The technician also disconnected the 12V battery while we await the replacement high voltage module to be delivered. This should prevent the vehicle from damaging the 12V battery.

 

[Maxx]

I'm also hopeful the remaining life of your Lightning is more reliable.

Do you have a feel for what the risk of Battery failure is? Like 50% in first two years and 20% after. Or 20% for 2022 builds and 30% for 2023..... I think my built day (Dec 5, 2022) was in a high risk group but I am not sure. Or is it a complete crap shoot. I like to worry but I am not sure how worried I should be.

 

[TaxmanHog]

Do you have a feel for what the risk of Battery failure is?

I have not been tracking this aspect.

 

[mgmessner89]

Add me to the list. 2023 XLT SR power reduced to 53 and charging faults. Dropping off at Peoria Ford here in AZ tomorrow. Been on software update 10.1.1 for a month so no new updates that would have caused this.
Build Date 10/23, purchased 7/24. 6900 miles.

 

[riceilove]

Following up from my comment on 12/29/2024 - It is now the 25th day in service (from 12/23/24), 32+ days cumulative within my first year of purchase, and I am still waiting for the dealership to complete the repair for a failed battery module. The other 7-8 days in service was due to issues with parking sensors, frunk, and an open recall.

I purchased the truck in Montana and registered in Colorado right away, but it seems like it qualifies as a lemon in both states, so I have just filed a request for a buy back. I just don't feel confident in the longevity of this truck anymore and will be looking to transition back into an ICE truck after the buy back is complete. If they reject my buy back request, I'll have to go through a lemon law attorney given I meet the legal requirements.

I love this truck so much and it sucks it has to go this way, but it's the right thing to do for myself.

 

[TaxmanHog]

Following up from my comment on 12/29/2024 - It is now the 25th day in service (from 12/23/24), 32+ days cumulative within my first year of purchase,................I love this truck so much and it sucks it has to go this way, but it's the right thing to do for myself.

Sorry for your experience, it is totally understandable, we need to have confidence in the vehicle and the manufacturers service model, this is another example of failure, come on FORD!

 

[Mwillselectric]

Following up from my comment on 12/29/2024 - It is now the 25th day in service (from 12/23/24), 32+ days cumulative within my first year of purchase, and I am still waiting for the dealership to complete the repair for a failed battery module. The other 7-8 days in service was due to issues with parking sensors, frunk, and an open recall.

I purchased the truck in Montana and registered in Colorado right away, but it seems like it qualifies as a lemon in both states, so I have just filed a request for a buy back. I just don't feel confident in the longevity of this truck anymore and will be looking to transition back into an ICE truck after the buy back is complete. If they reject my buy back request, I'll have to go through a lemon law attorney given I meet the legal requirements.

I love this truck so much and it sucks it has to go this way, but it's the right thing to do for myself.

I completely agree and understand. I just heard from Ford saying they accepted the submitted for a buy back, but another rep is supposed to call me in a few days with the terms or offer. So we will see what they come up with. It’s unfortunate because it seemingly is a nice truck, just the opposite of reliable with it being out of operation for more than 25% of the time I have owned it.

 

[GoodSam]

feel for what the risk of Battery failure is?

Remember, Ford said 4% of vehicles could have 1 or more battery module failures, I think? The big problem @Ford Motor Company is the lack of part availability and the out of service time makes the problem much more significant. See my tracking spreadsheet in my signature below.

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