SR to ER battery swap DIY project

[P-38]

No - Each module is somewhere in the range of 32V to 44V each. You need multiple of these modules (9) in series to get to ~350V - 400V range. You can't just take a single module out and "make it work".

You could take modules and build a 32Kwh pack and then run the EverDrive charge while driving.

You would not be easily able to tie the battery direct to the DC bus because of the above mentioned voltage difference.

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[jobofly79]

You could take modules and build a 32Kwh pack and then run the EverDrive charge while driving.

You would not be easily able to tie the battery direct to the DC bus because of the above mentioned voltage difference.

My thought wasn't necessarily on charging while driving but going off grid or somewhere that doesn't have charging stations.

 

[P-38]

My thought wasn't necessarily on charging while driving but going off grid or somewhere that doesn't have charging stations.

Fair. I was more saying yes you could take a module or two or more and make a pack. You would need to make your own BMS but can be done.

 

[Ted23Lightning]

following (even though I have ER now).

Same lol

 

[NW Ontario Ford Lightning]

Fair. I was more saying yes you could take a module or two or more and make a pack. You would need to make your own BMS but can be done.

Just buy some LFP cells, and make up a battery of any capacity you like. Then connect to an inverter to create the 240v AC supply and power the truck from the (much anticipated) bed mounted charging port...
Wait...EverDrive ? is this a new TM we should expect to be seeing ?

 

[P-38]

Just buy some LFP cells, and make up a battery of any capacity you like. Then connect to an inverter to create the 240v AC supply and power the truck from the (much anticipated) bed mounted charging port...
Wait...EverDrive ? is this a new TM we should expect to be seeing ?

@ZSC100 and martin rebuilds. The thread disappeared...maybe it violated something

 

[GoodSam]

Sure, not commenting about cost at all on my post but design of the pack. Following to see if in the future, you could in theory drop the pack, replace the 1 bad module and put it back together. Or if the whole pack is the same between sr and er where the sr has fewer modules, and adding a module into a blank spot gets you to full pack.

No - Each module is somewhere in the range of 32V to 44V each. You need multiple of these modules (9) in series to get to ~350V - 400V range. You can't just take a single module out and "make it work".

More details of the 3 pack sizes in this link:
https://www.f150lightningforum.com/...tery-size-determination-psa.27990/post-522875
4 or 5 long pouches per cell and 90 or 96 cells total in the 9 battery modules/arrays. 4 pouches is less kWh and 90 cells is less hp.
@TaxmanHog need to have a sticky on whatever is the best thread on battery pack types and their makeup!

 

[Yellow Buddy]

Be careful and good luck! Shame you can't just leave it in the bed and have an SR + ER. That'd be, what -- 560 miles of range? Give or take.

Just stack it on top of each other, that's basically what GM did with theirs..

 

[efme]

More details of the 3 pack sizes in this link:
https://www.f150lightningforum.com/...tery-size-determination-psa.27990/post-522875
4 or 5 long pouches per cell and 90 or 96 cells total in the 9 battery modules/arrays. 4 pouches is less kWh and 90 cells is less hp.
@TaxmanHog need to have a sticky on whatever is the best thread on battery pack types and their makeup!

Thanks for that link! Good read.

 

[TaxmanHog]

@ZSC100 and martin rebuilds. The thread disappeared...maybe it violated something

Here: Charging While Driving Works w/ Gas Generator in Bed (Range Extending for F-150 Lightning)

 

[kdkool]

More details of the 3 pack sizes in this link:
https://www.f150lightningforum.com/...tery-size-determination-psa.27990/post-522875
4 or 5 long pouches per cell and 90 or 96 cells total in the 9 battery modules/arrays. 4 pouches is less kWh and 90 cells is less hp.
@TaxmanHog need to have a sticky on whatever is the best thread on battery pack types and their makeup!

The lightning battery packs all come with 9 modules in series.

The SR is 98 kWh with (9) 4P10S modules. 333V nominal as a battery pack. 360 cells total.
The ER is 131 kWh with (8) 5P11S and (1) 5P8S. 355.2V nominal as a battery pack. 480 cells total.
The Flash is 123 kWh with (6) 5P11S and (3) 5P8S. 333V nominal as a battery pack. 450 cells total.

Makes sense that they'd make the Flash with more of the 5P8S smaller packs to increase the production quantity (to reduce mfg costs) of that module configuration and to further reduce any production constraints on the 5P11S modules.

 

[PreservedSwine]

Good luck with this swap. It makes sense Ford doesn't want anyone getting into Forscan and bricking their truck. Those with the knowledge, skill, and expertise are able to safely operate under a different set of rules. Thanks for making this experience public, can't wait to sit shotgun and read about every step of this. I would love to do the same. THANK YOU!

 

[NW Ontario Ford Lightning]

I was going to say: How did you get a "2003" F-150 Lightning Pro SR" - LOL. {2023 perhaps?}

 

[taraafico]

Wishing you best of luck.

 

[Ynnhojnorood]

At this point we are talking about an F150 that weighs as much as an F350. The Lightning is already a ton over an ICE F150. Tom's video about local street weight limits brings EVs into a new light. Those Chevy, GMC and Hummer vehicles are over 4 tons. I think the F150 nailed it by keeping it close to 3 tons with a bit less range. All that extra weight for an extra few miles? Did you see the Hummer? It's like the old GM Hummers as far as inefficiency.

I’m now in a Sierra EV (Max) and get the same mi/kwh as I did in the lightning. I can’t imagine the Hummer is that much worse.

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