Charge to 100% on L2 charger, but GOM shows 84% on startup

[frautumn]

How would one know if they have this problem if they only charge to 50 or 60 percent regularly? I only charge above 75 if I am going on a long trip (truck is usually driven locally a few days per week).

I would have never known if I didn't charge above 70. When I charged to 80, it slowed down significantly around 77% or so, which was noticeable so that would be how I would have figured something was wrong if I had only been charging to 80. There were no errors or malfunctions of any kind reported.

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[TaxmanHog]

There were no errors or malfunctions of any kind reported.

That is very odd that no errors were triggered, so many reports of module failures usually resulting in reduced motor energy, then tripping the code and subsequently restricted charging.

 

[GoodSam]

Got my Lightning back today, they replaced Module #9 (on warranty of course). My previous module replacement (March 2023) was Module #8. I wonder how many others have had more than 1 replaced??

See my spreadsheet in my signature below and look for the red highlighted lines...too many! You are now included.

 

[CD4TNF]

Good work @GoodSam! That's quite a tracking sheet you have going.

 

[Texas Dan]

Just got word back from the dealer and it looks like my Lightning has an array (module) failure. It’s going to a week for delivery of the parts and a couple of more days to install and test. Okay, somebody tell me what’s the difference between a module and an array? My service writer was really struggling with that question and didn’t seem to know what a module was.

 

[CD4TNF]

Here's a short vid on replacing the Lightning's battery module.




Somewhere the answer is likely in Munro's battery teardown.

 

[VTbuckeye]

It's recomended to charge to 100% on occasion, and it would answer this question for you. There is no harm in charging to 100% once in a while.

In your case charge it up to 100% the night before you are going to do some driving, that way it isn't sitting for multiple days at 100%. Be warned though, it takes many hours to go from 99% to 100%, so make sure you give it enough time.

Yes, I am aware of how long it takes. I have no reticence when it comes to charging to 100 percent when traveling, but there is no need to leave the truck at a high state of charge regularly. It probably goes to 100 quarterly and has been into the single digits once.

 

[frautumn]

Okay, somebody tell me what’s the difference between a module and an array?

Not sure I've heard it called an "array" before, but I'm assuming they are just using a different word for module.

Each truck has ONE battery pack
Which contains 9 modules
Each module contains many cels (20 or 30 ish I think).

If a cel goes bad, they have to replace the module that contains that cel. Presumably they send that module back to the factory where the good cels can be separated and used in refurbished modules.

I'm no expert on this so somebody can correct me if I'm wrong.

 

[TaxmanHog]

If a cel goes bad, they have to replace the module that contains that cel. Presumably they send that module back to the factory where the good cels can be separated and used in refurbished modules.

I'm no expert on this so somebody can correct me if I'm wrong.

I believe the defective module is sent for study of failure, then destructive reclamation of minerals

 

[GoodSam]

Not sure I've heard it called an "array" before, but I'm assuming they are just using a different word for module.
Each truck has ONE battery pack
Which contains 9 modules
Each module contains many cels (20 or 30 ish I think).

See this link to @Ford Senior Master post on the # of cells and types of modules and various combinations.
https://www.f150lightningforum.com/...dules-starting-with-chatgpt.21142/post-488187

I thought that array might refer to a battery pack of the 9 modules, but not sure how @Ford Motor Company uses the word in this post below--I am thinking array=pack, not one of the 9 modules.
https://www.f150lightningforum.com/...-high-voltage-battery-cells.25351/post-487796

 

[Texas Dan]

The dealership just called and said my truck is ready. I think my service writer learned a little because he fessed up and said an array and a module are the same thing. He said the voltage balance on module #2 was out of tolerance and had to be replaced.

 

[Texas Dan]

Got the truck back and it seems to work fine. It was 65% SOC so I took to an EA station to charge to 70%. I’ve got it on my Charge Station Pro right now and it’s already above 84%’going to 90%.

The whole process went pretty smooth. Once the dealership received the module it only took them about a day to install it and have the truck ready for me to take back. I think Ford did a good job of training these technicians.

 

[Grumpy2]

With such a quick turn around they may have not vacuumed all of of the air out of the cooling system, so you might want to keep a close eye on the coolant reservoir. You can buy a gallon of the proper coolant and keep the reservoir at the middle in the reservoir if you see the level falling.

 

[bordner42]

Damn, I just noticed this issue happening to myself this week after noticing that the battery % was consistently showing 2-3% lower than the original estimate on it's first drive after being on the charger to and from work. Meaning that on the way there it was 2-3% less than estimated and at estimate on the way back. Paid attention to it today, and it showed being at 90% then dropping to 88% almost immediately. I've already had two battery modules fail, including one that just finished being repaired only three weeks ago, so it's pretty concerning that there could be a third bad already...

 

[Grumpy2]

Ford has said it may take up to 22 days after a module has been replaced for these issues to settle down. Search for SSM 52039. I hope this is your issue.

https://www.f150lightningforum.com/...ction-reduced-power.12873/page-47#post-409941

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