023 Lightning (Build 08/23) – No Heat / No Defrost Heat – Dealer says “failed heater assembly” (any insight?)

[Balke]

An interesting note that someone with more knowledge than me has insight on, the removal instructions state that its for Vehicles Built From: 1-August-2023. What was different with the previous builds? I dont think I can pull that up because I only see things regarding my truck.

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[TaxmanHog]

An interesting note that someone with more knowledge than me has insight on, the removal instructions state that its for Vehicles Built From: 1-August-2023. What was different with the previous builds? I dont think I can pull that up because I only see things regarding my truck.

Not sure, it could be minor procedure changes for 2022, early 2023.

The redesign for the Heat pump systems rolled out in moel year 2024 which began production on 12/18/2023

 

[Balke]

I think I have done all I can do unfortunately. Spent many hours on phone with BEV support. Countless messages to service provider. Requested to speak with service manager, general manager... emailed them both, never got a response. Filed complaints through ford, no replies, no call backs. Going on a road trip to the mountains next weekend and will need repair done for comfort and safety of the battery.

 

[TaxmanHog]

I was just wondering which # the PTC was. edit: Which I now see is # 9 Or is it # 23? Thanks.

9 is the PTC
23 is the cabin heater core

 

[ZSC100]

If you are in a bind and need a truck, start calling all dealerships close to you, increase your radius until you find a good dealer with a good service manager.

Tell them you need a loaner (truck) and your truck will be in the shop for at least a week.

Ask questions like: How many E-certified techs do you have? How many Lightnings have you worked on?

Tell them you have a warranty issue that is in a gray area of post 36kmi but < the EV powertrain warranty and you need someone knowledgeable in the complete understanding of the EV powertrain of the Lightning. Even if you have to drive 2hrs to get to this dealer, you'll get a loaner and you'll get better results. The reason you need all of is squarely because of this symptom: "The battery is not able to precondition or maintain temperature in cold weather resulting in the inability to take trips that require fast charging"

 

[Balke]

Not sure, it could be minor procedure changes for 2022, early 2023.

The redesign for the Heat pump systems rolled out in moel year 2024 which began production on 12/18/2023

It makes me wonder if the earlier versions (cabin heater) are covered and the decided the newer ones are not for some reason.

Wish I had a way to search what parts are covered under warranty. Anyone in the forums with inside access able to check this out?

The part numbers that I can find, which are the same part are:
LX6Z-18K463-A
RL3Z-18K463-A
I really don't understand why part numbers are different and even the name of the part changes a bunch in the literature.

EDIT, under closer inspection they do look different.

 

[ZSC100]

It makes me wonder if the earlier versions (cabin heater) are covered and the decided the newer ones are not for some reason.

Wish I had a way to search what parts are covered under warranty. Anyone in the forums with inside access able to check this out?

The part numbers that I can find, which are the same part are:
LX6Z-18K463-A
RL3Z-18K463-A
I really don't understand why part numbers are different and even the name of the part changes a bunch in the literature.

EDIT, under closer inspection they do look different.

You shouldn't go down this road or waste any time on it. What matters is that you have a bad PTC heater within your HV battery's warranty and a bad PTC heater can negatively affect your HV battery. It's a simple as this. Find a different dealer and take it in with the symptom of "can't fast charge in cold weather" and "very poor performance in cold weather"

 

[YellowstoneLightning]

The same thing happened to my 23 lariat er. Mine occurred at the start of an extended cold spell in Montana. It was the PTC heater and my battery was getting cold also, which resulted in all kinds of codes discovered at the dealer. I seem to remember the service folks saying it would have cost me around $1,500 if it had not been covered under the 3yr/36,000 mile warranty. This happened about a year ago and it has been fine since.

 

[WXman]

My summer 2025 build truck didn't even make it 5,000 miles before the heater assembly failed!

 

[Balke]

Yeah. Its obviously an issue with these trucks. They wont acknowledge that it could damage anything if i drove it as is, so my hand is forced into a repair bc all the research i have sone seems otherwise.

My only hope is that I can keep contacting ford and get on the line with someone that can make it right.

I asked to keep the old part, they said I have to pay the 125 core charge but its seems worth it if it helps my case.

 

[TaxmanHog]

I asked to keep the old part, they said I have to pay the 125 core charge but its seems worth it if it helps my case.

Wondering why there is a core fee on the part?

I figured it was disposable after failure!

Maybe it can be reconditioned?

 

[Balke]

Wondering why there is a core fee on the part?

I figured it was disposable after failure!

Maybe it can be reconditioned?

During my research I did find one listed refurbished on ebay I think. Probably that solder joint that was the reason for recalls

 

[ZSC100]

I did notice that while I was driving without heat for a week or so the battery temp was low and I have never noticed that before. It would always be dead in the middle. Could be that I use the scheduled trip everyday and while it was working it gets things to proper temp. My thought is if I opted to not fix this issue and the battery wasn't able to manage cold temps properly that this should fall under the 100k battery systems warranty. Could just be wishful thinking on my part.

As I was reading back through all this I see that you used conditioning everyday, maybe there is a issue with the control circuitry that is hard on the PTC heater. I have never once used departure schedule preconditioning, And very rarely use preconditioning period. I do start my truck to condition the cab everyday it's below 50. I have 140kmi, 4winters, never a single issue with heat. The heater is awesome! Warms up quicker than any ICE I've ever had.

You need to pick up your vehicle in leave that dealer.

I'm telling you, you will have better luck claiming your high voltage battery cannot precondition and it is causing performance issues. Once they diagnose the bad part under this symptom, it will be covered.

 

[Balke]

As I was reading back through all this I see that you used conditioning everyday, maybe there is a issue with the control circuitry that is hard on the PTC heater. I have never once used departure schedule preconditioning, And very rarely use preconditioning period. I do start my truck to condition the cab everyday it's below 50. I have 140kmi, 4winters, never a single issue with heat. The heater is awesome! Warms up quicker than any ICE I've ever had.

You need to pick up your vehicle in leave that dealer.

I'm telling you, you will have better luck claiming your high voltage battery cannot precondition and it is causing performance issues. Once they diagnose the bad part under this symptom, it will be covered.

I agree with you, I just don't have the time to ship to other dealer, they diagnose, then go through this whole thing over again.

I was really hoping my case would go to someone higher than the service provider but the stop gaps Ford puts in place make it impossible to talk to anyone who can make a decision outside of what is on their screen.

Been over a week now and I am ready to have my work truck back.

 

[TaxmanHog]

I have never once used departure schedule preconditioning, And very rarely use preconditioning period. I do start my truck to condition the cab everyday it's below 50. I have 140kmi, 4winters, never a single issue with heat.

Also four New England winters, using remote start or scheduled departure time (mostly unplugged so it's really only cabin warming) multiple times daily, still going strong with 28,974 miles as I write this.

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