Rear motor replacement pic

[Rlevans]

Wow, sorry. I assume you took it to Lewiston? They too must be frustrated. I just reviewed your previous posts, sure seems to be a software issue, perhaps after that update.

Perhaps a dealer in the Tri-Cities?

Bought from Pullman WA dealer and I think for the most part they are doing what they can.
Unfortunately most of the waiting has been on Ford field service engineer. Waited around 30 days to hear back from them before they could proceed with next steps.

They have tried updates on the modules but I don't think they have tried reprograming which is what I have suggested at this point.

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[ChrisCon]

Can you share with us the codes or PM me your vin?

 

[Jarratt]

Thought I’d post a pic of rear motor out of the truck. I couldn’t find any posts of this having been done before.
Rear motor is being replaced in attempt to fix my 1 pedal drive fault.

Apparently the module in question doesn’t come separate and the entire assembly gets replaced.

I'm gobsmacked! I would have bet that a 1 pedal drive fault was a software issue whose solution could have involved OTA resets. I'm at a loss to try to figure out how a mechanical issue with the motor would trigger that problem.

 

[scruvs]

I bought an ostensibly factory service manual from https://www.factory-manuals.com/

I was a little dubious at first, but after reading through parts of it, I think it is legit. I have used it for a couple of things already. It was about $130. I am a hands-on engineer type and I really like having a manual.

What kind of things have you used the manual for? I’m trying to get an idea of the complexity of DIYing this EV compared to typical ICE maintenance of replacing fluids, sensors, pumps.

 

[scruvs]

I just lightly scanned this thread, but I'm assuming they tried a software reinstall or fix? I would think there would be a sensor somewhere too which I'm sure they checked.

Not for these trucks, but in general, after software, I tend to blame sensors.

I’m trying to think what sensor there could be that isn’t fully software controlled, with the accelerator pedal or otherwise.

And, if it’s not the motor or software, I also begin to thing about data connections through wiring harnesses and electrical connectors.

Good luck. Curious to hear what they find.

 

[Rlevans]

I'm gobsmacked! I would have bet that a 1 pedal drive fault was a software issue whose solution could have involved OTA resets. I'm at a loss to try to figure out how a mechanical issue with the motor would trigger that problem.

I am surprised also. One of the stored codes did indicate a control unit on the rear motor communication issue and the part isn’t available separately.

I still think it’s a software or programming issue.

They have tried updating the modules but I think that would only update them to the stores as-built values that are available to the FDRS as I understand it.
If the as-built data is corrupted it seems like it would just keep reinstalling it ?

It seems like the modules that control 1 pedal function are the APIM and BCM

I’m trying to get them to reset the values of these with known good as-built values, but not sure if that’s a thing…

 

[biers]

If you’re past 30 days I’d invoke a buy back via lemon law and buy a new one with fresh tax credit and 0% financing.

 

[Taddio]

What kind of things have you used the manual for? I’m trying to get an idea of the complexity of DIYing this EV compared to typical ICE maintenance of replacing fluids, sensors, pumps.

I had some equipment temporarily installed by a non-ford mechanic. The mechanic failed to connect the reverse sounder control module. I used the manual to locate the module and reconnect the cable.

I mainly use the manual to become familiar with the vehicle so that I can understand any work that may need to be done to it. Plus, I just like having the manual because I am really into EVs!

 

[Rlevans]

This might be a long post so TLDR: Truck is fixed!

Got the call yesterday that they had potentially found the problem and that they were out test driving it.

Spoke with service advisor this am and he told me they found a broken wire in connector C118 pin #9 which supplies power to fuse 24 to the SOBDMB. It was reportedly tricky because the wire was just intact enough to test ok but when load tested would not supply enough power and would fault.
(It was hanging on by maybe one or two strands I guess! )

So they fixed the wire and faults are gone. They returned the truck to me this afternoon and its working flawlessly. I even tried charging on level 2 and 3 and both work fine with no faults.

For those not familiar with the symptoms described in my other posts:

1. No 1 pedal drive, would immediately fault when put in gear
2. Cruise would not hold set speed
3. Level 3 charging would set an error saying "service soon" and limit power to 50%

Weird thing is I could get 1 pedal to work and truck would behave normally if I followed a specific startup sequence:

Start truck in accessory mode- turn off 1 pedal in settings- Start truck normally- shift into neutral- turn on 1 pedal.
I learned this would always fail the first try. So I would shut the truck off, open and shut door and wait for truck to completely shut down, repeat the sequence and it would work.
I don't even remember how I learned this...

Big thanks to ChrisCon who looked into things on FDRS.

I'm hoping that by posting this it might help someone in the future.
This forum and members have been and I'm sure will continue to be essential in figuring out problems like these in this new generation of vehicles.

 

[TaxmanHog]

This might be a long post so TLDR: Truck is fixed!

Got the call yesterday that they had potentially found the problem and that they were out test driving it.

Spoke with service advisor this am and he told me they found a broken wire in connector C118 pin #9 which supplies power to fuse 24 to the SOBDMB. It was reportedly tricky because the wire was just intact enough to test ok but when load tested would not supply enough power and would fault.
(It was hanging on by maybe one or two strands I guess! )

I hope it's a one in a one of a million issue and not a harness design issue with incorrect tension / slack in the wire loom.

 

[MidAtlanticLightningClub]

Is there a service interval for changing the fluid and filter?

It's 200,000 on the Mustang Mach E.

 

[Rlevans]

I hope it's a one in a one of a million issue and not a harness design issue with incorrect tension / slack in the wire loom.

Me too, I'm trying to find the location of that connector to see what I can do if anything to protect it.

 

[BuildBackBadder]

Lesson learned for DIYers and Ford techs. Before you perform such a large repair, check the wiring and connectors. That includes an electrical AND visual inspection of the connectors.

 

[GarageMahal]

Lesson learned for DIYers and Ford techs. Before you perform such a large repair, check the wiring and connectors. That includes an electrical AND visual inspection of the connectors.

When a sensor says an expensive part has failed always check the sensor first

(advice I wish I took more often)

 

[Maxx]

When a sensor says an expensive part has failed always check the sensor first

(advice I wish I took more often)

Unless the labor cost for replacing/fixing the expensive part is higher and the customer is more clueless than you are.

Kiding aside, what you are saying is true and it is wise to practice it, but it is easy to be Monday night quarterback for us. Most trouble shooting in practice is based on having experience with a particular kind of problem with similar hardware/software. For those of us that don't have that experience, we try to borrow other's from YouTube or forums. When it comes to Lightning, that often does not exist and these techs have to be the trail blazers. We should cut them some slack.

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