Truck refuses to charge past 84-87%

[hashtagemmer]

So my truck refuses to charge past 84-87%. As you can see, it is set to charge to 100%. The vehicle “thinks” it chargers to 100%, as soon as you unplug and turn the truck on, it immediately drops back to that 84-87%.

No errors shown in the vehicle or ford pass app.

To troubleshoot all charging location profiles have been removed. There is no schedule charging on either the vehicle or charger side. I have verified the issue continues on my L2 48A hardwired charger (ChargePoint home flex), ford mobile charger on a NEMA 14-50, and a DCFC.

Has been in service for 24+ days now and been escalated to Ford Engineering and their “token based advanced log gathering”

Anyone else having a similar issue?

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[TaxmanHog]

There have been a few others with this situation, it be an issue with your onboard charger.

 

[hashtagemmer]

There have been a few others with this situation, it be an issue with your onboard charger.

It charged without issue from single digits up to the 84-87%. It doesn’t appear to present as an issue with the onboard charger?

 

[CurtisW]

Exact same issue. Had a bad cell in module 2.
Dealership replaced the module under warranty
If your dealer is having issues give them this
SSM 53208
"Some 2022-2023 F-150 Lightning vehicles may exhibit a reduced distance to empty (DTE) projection, a high voltage (HV) battery pack state of charge (SOC) that drops from 100% to less than 90% within 60 seconds of being driven, and an inability to reach a target SOC using the scheduled charging feature without any diagnostic trouble codes (DTCs) in the battery energy control module (BECM). This may be due to an issue in one or more cells within the HV battery pack. To correct the condition, run the "BECM Battery Health" application using the latest software version of the Ford Diagnosis and Repair System (FDRS). If any cells are identified as exceeding state of charge and/or capacity thresholds, refer to the Workshop Manual (WSM), Section 414-03A High Voltage Battery, Mounting and Cables > Diagnosis and Testing > High Voltage Battery, Mounting and Cables - Electric > Pinpoint Test AP > Step AP4 and continue diagnosis. If all cells are within state of charge and capacity thresholds or DTCs are present in the BECM, refer to the WSM for normal diagnosis."

Mine was also an atlas blue 22 Lariat with around 65k miles
I bet your SOH is reading perfectly fine LOL I keep telling peolpe that number is meaningless.
Module SOC variation is what tells you a cell is going bad

 

[hashtagemmer]

Exact same issue. Had a bad cell in module 2.
Dealership replaced the module under warranty
If your dealer is having issues give them this
SSM 53208
"Some 2022-2023 F-150 Lightning vehicles may exhibit a reduced distance to empty (DTE) projection, a high voltage (HV) battery pack state of charge (SOC) that drops from 100% to less than 90% within 60 seconds of being driven, and an inability to reach a target SOC using the scheduled charging feature without any diagnostic trouble codes (DTCs) in the battery energy control module (BECM). This may be due to an issue in one or more cells within the HV battery pack. To correct the condition, run the "BECM Battery Health" application using the latest software version of the Ford Diagnosis and Repair System (FDRS). If any cells are identified as exceeding state of charge and/or capacity thresholds, refer to the Workshop Manual (WSM), Section 414-03A High Voltage Battery, Mounting and Cables > Diagnosis and Testing > High Voltage Battery, Mounting and Cables - Electric > Pinpoint Test AP > Step AP4 and continue diagnosis. If all cells are within state of charge and capacity thresholds or DTCs are present in the BECM, refer to the WSM for normal diagnosis."

Thanks! I just texted that to my service advisor. I had a bad module in November but got errors in the vehicle and ford pass app for that one. No errors showing this time around.

 

[TaxmanHog]

It charged without issue from single digits up to the 84-87%. It doesn’t appear to present as an issue with the onboard charger?

If you have an ER there are two charger, one is malfunctioning, or there is an issue with the battery modules, surprised you haven't tripped a wrench MIL warning yet!

 

[CurtisW]

Also your AC charging is probably slowing down way early around 80% and DCFC is greatly reduced around 60%.

Mine was exactly the same issue. No warnings or error codes. It would finish charging early then drop to 85% as soon as put in drive. I drove it about 1k miles before taking it to the dealer. Tried supercharging just to see what would happen and it initially would pull around 120kw then above 60% would drop below 50kw.

 

[bmwhitetx]

I often scroll down on these threads and you will see a section called Similar Threads. There is one from @WileyKyle from 2023 that is almost exactly like yours. Unfortunately he never posted the outcome. But others on that thread suggested bad module.

I agree with @CurtisW , take a look at the HVB SOC module variation (%). Mine stayed under 0.6% until a module went bad and it jumped to over 4%.

I realize it's it the shop but maybe you screenshot the other screens as well.

 

[CurtisW]

I often scroll down on these threads and you will see a section called Similar Threads. There is one from @WileyKyle from 2023 that is almost exactly like yours. Unfortunately he never posted the outcome. But others on that thread suggested bad module.

I agree with @CurtisW , take a look at the HVB SOC module variation (%). Mine stayed under 0.6% until a module went bad and it jumped to over 4%.

I realize it's it the shop but maybe you screenshot the other screens as well.

I noticed the problem when module SOC variation was above 7% it was almost at 9% when I took it to the dealer. Initially wouldn't charge past 88% and then every few days lost another % until it was at 85% and I brought it to the dealer. My SOH was 99.5% with this issue and voltage variation was also very good. Prior to the issue my module SOC variation was 0.6% after the repair its at 3.3% but that's likely normal due to 1 new module and 66k miles on the others. MY SOH after the replaced module is 99%

 

[WileyKyle]

I often scroll down on these threads and you will see a section called Similar Threads. There is one from @WileyKyle from 2023 that is almost exactly like yours. Unfortunately he never posted the outcome. But others on that thread suggested bad module.

I agree with @CurtisW , take a look at the HVB SOC module variation (%). Mine stayed under 0.6% until a module went bad and it jumped to over 4%.

I realize it's it the shop but maybe you screenshot the other screens as well.

I did in fact have a bad module.

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