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riceilove

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Just had to drop my truck off for the second time now with this issue, confirmed to again be a battery module failure and an estimated two weeks for a new one to arrive. Pretty bummed that I was right about it being a battery issue again.

Regarding lemon laws, does it backdate to the first time I experienced this issue or is it the present time. Asking, because I'm less than a month past two years of ownership and only a couple thousand miles past 20,000. Not really sure about the process to make it a lemon or what comes with it, but looking for opinions/options (if I even qualify) if this is another lengthy wait time for repair. Thanks!
It depends on your state. E.g. Colorado has a 24+6 months law where if the first time the issue occurred was within 24months or 20k (or 24k?) miles, you have up to 30 months from purchase date to file a lemon law buyback.
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bordner42

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It depends on your state. E.g. Colorado has a 24+6 months law where if the first time the issue occurred was within 24months or 20k (or 24k?) miles, you have up to 30 months from purchase date to file a lemon law buyback.
Bought in NJ and registered in Ohio if anyone has any experince
 

bordner42

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It usually adheres to the state you purchased in, so NJ in your case. My quick search says 2yr/24k miles.
Yeah I'm doing additional research and I'd be fairly upset if it was didn't qualify because I was 2 years + 2 days and 224 miles over.
 

Piquette

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Sorry to hear that you have also lost two battery modules in 24k miles. There are two issues here. First, you are out your truck for at least 2 weeks, and second, there are still 7 other original battery modules in your truck, any of which could (and probably will) go bad at any time. I have become leery of taking my truck far from home for this reason. Meanwhile Ford is stalling on my request for a buy back. 😟
 

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bordner42

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Sorry to hear that you have also lost two battery modules in 24k miles. There are two issues here. First, you are out your truck for at least 2 weeks, and second, there are still 7 other original battery modules in your truck, any of which could (and probably will) go bad at any time. I have become leery of taking my truck far from home for this reason. Meanwhile Ford is stalling on my request for a buy back. 😟
Could only be 6 original battery modules after this! They didn't say which failed, so might not even be the prior replacement one that failed.
 

GoodSam

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Could only be 6 original battery modules after this! They didn't say which failed, so might not even be the prior replacement one that failed.
there are 9 battery modules, so could be 7 or 8 original modules still left after repair. There has been one report of someone having 3 modules replaced (see my tracking spreadsheet in my signature below). Speaking of which, what is your Build Month/Year shown on your driver's door sticker at the top? Early 2022's seem to have the worse luck, but even 2024's have been bit by this long time delay repair. If the battery module replacements could be done in a few days, instead of weeks, the pain would be less severe for everyone, including Ford for fewer lemon buybacks. @Ford Motor Company
 

Wonko

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there are 9 battery modules, so could be 7 or 8 original modules still left after repair. There has been one report of someone having 3 modules replaced (see my tracking spreadsheet in my signature below). Speaking of which, what is your Build Month/Year shown on your driver's door sticker at the top? Early 2022's seem to have the worse luck, but even 2024's have been bit by this long time delay repair. If the battery module replacements could be done in a few days, instead of weeks, the pain would be less severe for everyone, including Ford for fewer lemon buybacks. @Ford Motor Company
Have you looked at how many of the failed modules are related to battery cooling system failures? Anecdotally I have seen several cases where either a diverter valve or a heater assembly (like my case) was correlated with bad modules. Presumably the cooling system is necessary, especially while charging, so it stands to reason that cooling system failures could be at the root of at least some of the module failures.
 

GoodSam

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cooling system failures could be at the root of at least some of the module failures.
Yes, that would make sense. The 96 battery cells, made up of either 4 (SR) or 5 (ER) pouches, expansion and contraction, due to charging and temperature variations, are being stressed. Also, @MickeyAO implied that testing showed bigger "depth of charge"s (say, 10-100% vs 50-70%) were more stressing on the batteries. Normally, the cooling & heating system should minimize the temperature factor.
 

Wonko

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Yes, that would make sense. The 96 battery cells, made up of either 4 (SR) or 5 (ER) pouches, expansion and contraction, due to charging and temperature variations, are being stressed. Also, @MickeyAO implied that testing showed bigger "depth of charge"s (say, 10-100% vs 50-70%) were more stressing on the batteries. Normally, the cooling & heating system should minimize the temperature factor.
If you think about the concept of people who have had multiple modules fail, you would think Ford would have a 6 Sigma team all over data collection trying to get to root cause on these failures. The numbers of just casually voluntarily reported failures to a Google sheet on a forum, which is probably a fraction of actual failures, out of the fairly small population of vehicles in the field suggest they have a pretty big issue on their hands.
 

sooomanypuppies

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Update: Here's a quick report on my surprisingly positive experience with the dealer. First off, they sent a valet service to pick up the vehicle from my home. Later that day, the Service Advisor called me with the diagnosis: Bad HVB module #3. They ordered the parts and said it would be 3-5 days. He said I could drive the truck until the parts came in. I started out with around 75% and he requested that I return it with at least 50% SOC.

While the vehicle was there, they performed two recalls: 24B56 - Front parking sensors, and 24P24 - Front hatch control module. The valet service then delivered the truck back to my home. Both recall procedures went well. I did notice that the red LVB battery dash light was on. I plugged the charger in and was surprised that the red ring of death was gone and the truck actually started charging!

The next day, the SOC was at 90%, the LVB battery was recharged, and the red dash light was off. However, that was short-lived as the red ring re-appeared and the powertrain malfunction notification returned when I tried to charge again. But I was still able to drive with no problem.

5 days later the parts came in and I took it back for the module replacement. They said it was a very complicated process and could take 3-5 days. I was expecting the worst. To my great surprise, they called later that day and said it was all done! They also did the 24S76 Upper control arm nut replacement at that time.

So I'm back on the road after less than a week. They performed 3 Recalls and a HVB module replacement. I'm extremely pleased with the exceptional response by the dealer (Larry H Miller Ford, Draper UT). I don't know how they could have done any better. Hopefully I can still say that after driving it more, but so far, so good!
Oh Man! You can add me to the same spreadsheet. I am scheduled for serviced to START looking into this 57% maximum battery issue. This started out of the blue. From reading all of these posts, it encourages me to make sure I have everything documented and potentially prepare for very drastic changes (e.g. buy back is crazy to think about).
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