Cell undervoltage of one cell - charging no longer possible

[Bernd]

I've had a 2023 Ford F-150 Lightning Lariat since this year.
I imported the Lightning from Florida to Germany.
A very cool car, I love it.

A few weeks ago, a "Service soon" message appeared. The battery had limited capacity and could only be charged to 60%.
Then things deteriorated rapidly; the battery capacity dropped dramatically, and eventually, charging was no longer possible.

The Ford dealer found the problem:
One cell in module 6 has a very low voltage of 3.34V, while all the other cells have 3.86V.

Module 6 needs to be replaced.
The Ford dealer can't do the work; they lack the necessary tools.
Furthermore, Ford doesn't offer a warranty in Germany.

Can anyone tell me the part number for module 6?
What other parts do we need? A cooling plate, thermal paste?
Where can I order the parts in the USA?

I'm hoping for some help, guys.

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[PJnc284]

on the brightside, it looks like it's on the top rear

 

[TaxmanHog]

I'd hope the Ford Germany parts folks could source all the part's you'll need.

The big question is, do you have access to an independent or other brand service shop that has the necessary tools, heavy handling equipment and technical devices to calibrate the replacement module to the rest of your pack?

Are there other Ford BEV service centers in the rest of of the EU, such as those countries that formally sell the Lightning which you could hire to do the work?

 

[Grumpy2]

In addition to all of above, I would recommend you try to start a PM conversation with this poster. He has first hand knowledge of successfully removing and replacing the battery on his own.

https://www.f150lightningforum.com/forum/threads/sr-to-er-battery-swap-diy-project.31656/

 

[Gimme_my_MME]

In addition to all of above, I would recommend you try to start a PM conversation with this poster. He has first hand knowledge of successfully removing and replacing the battery on his own.

https://www.f150lightningforum.com/forum/threads/sr-to-er-battery-swap-diy-project.31656/

Replacing a module is VASTLY different from replacing an entire pack

 

[vvgogh]

The dash should produce a warning that says "service vehicle soon." You can use an ODB2 scanner to clear the error. This will let you resume charging somewhat normally: full speed to DC 80% and AC to 92% or so. Above these, charging will slow more than a normal, healthy vehicle as the power systems continue protecting the battery due to the out of family cell voltage.

The error will of course return until the repair is complete. But, you can keep using it while sorting how to get it repaired by clearing the error. I was able to drive and charge 2,000 miles after the error cropped up until after a trip.

 

[Heliian]

I'd hope the Ford Germany parts folks could source all the part's you'll need.

You'd be lucky if they even had contact info.

Try that first then contact a North American dealer. Definitely check both Canadian and usa dealers to see which has the better pricing and exporting costs.

 

[RLXXI]

Push cones to shove you may have to bring the truck back to the states for repair.

 

[Bernd]

Thanks for the tips.
The vehicle is currently no longer activating the high-voltage side. The error codes are shown in the images below.

Yes, we watched the YouTube video about the 2022 module replacement, as well as others.

We already have a lift and will be getting a 1000kg scissor lift.

Yes, it won't be easy. But we think we can manage the electrical and electronic aspects with the help of the Ford FDRS and the VCM3. We'll probably have to purchase the software and hardware.

Do you have any good recommendations for a source?

One problem is the parts. I suspect that once we have the part numbers, they won't be available in Europe.

Your idea of asking in Switzerland or Norway isn't bad. The F-150 Lightning was officially sold in those countries.

Is there a website where you can search for Ford F-150 parts without having to be a dealer?

Does anyone know the part numbers for the battery modules?

 

[Bernd]

Hey guys,

We're helping ourselves. We removed the battery and opened module #6. We found that we could access cell pack #66 from the side.

After removing the module from the battery pack, we were able to rebalance cell 66.

Using the Autel diagnostic tool, we then charged the Ford while monitoring it and cleared all the error codes. Now it's running perfectly again.

We are continuing to monitor and test; if a problem arises with the module, it will be replaced. It arrived from Ford USA this week.

 

[chriserx]

Hey guys,

We're helping ourselves. We removed the battery and opened module #6. We found that we could access cell pack #66 from the side.

After removing the module from the battery pack, we were able to rebalance cell 66.

Using the Autel diagnostic tool, we then charged the Ford while monitoring it and cleared all the error codes. Now it's running perfectly again.

We are continuing to monitor and test; if a problem arises with the module, it will be replaced. It arrived from Ford USA this week.

I was extremely curious if this would actually work, most 'failed' modules have been slightly low, but still well within acceptable range for the chemistry, keep us posted. Have my fingers crossed for y'all.

 

[Bernd]

I was extremely curious if this would actually work, most 'failed' modules have been slightly low, but still well within acceptable range for the chemistry, keep us posted. Have my fingers crossed for y'all.

Dear,
approximately 10 days and 600 km after re-balancing, module 6 is behaving completely normally. We will, of course, continue to monitor it.

So far, the Ford has only been charged at a maximum of 50 kW DC.
We'll conduct a test at maximum power next week; we'll see.

What's striking is that after 10 days, the BMS adjusted the SoH from 99% to 97%. Apparently, there's something unusual happening with the dynamic monitoring by the BMS.

.

 

[GoodSam]

Apparently, there's something unusual happening with the dynamic monitoring by the BMS.

You showed a problem code of P0DE6. Is that related to the coolant diverter valve?

 

[Aminorjourney]

I am surprised that Ford Norway were not able to help.

Additionally, Ford sold the Lightning in Austria or Switzerland IIRC?

 

[El Duderino]

Hell yeah, this is awesome. Great to see someone not afraid to take matters into their own hands. Very happy your were able to get the cell individually charged above the low voltage threshold.

There's a whole community of people doing this exact same thing to the early Tesla model S packs and I think it's neat that we're finally starting to see some folks in the Lightning community doing the same thing.

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