Battery failure issue: 2 battery cells need to be replaced

[Heliian]

Faults - no, but… My updates are set to 1AM, but my truck does updates on YOLO schedule.

Updates that don't require downtime happen as they come in. Only updates that require downtime adhere to the schedule.

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[MountainAlive]

My 2022 F150 with 113,000 miles was parked while I was on a cruise. It had an automatic update while it was parked. When I returned home and started it, I got the PowerTrain Malfunction light and warning. … The error codes the dealer pulled are PCM C0630:00: 66 and PCM C0604: 00: 68

I tried looking up these error codes and I’m getting conflicting results but I’m not a dealer tech. But it hints to me a possibly being a bad 12 volt battery. Since the cost of this repair is extremely high I would try to get another dealer to give you a second look. At least that’s what I would do.

 

[RickLightning]

I would get the BEV team involved, and ask for Ford Engineering to look into the errors.
As to coverage, anyone buying an extended warranty should of course read it. I plan to not own any EV past the 8 year / 100,000 mile mark unless battery/packet replacement costs are reasonable.

 

[Zprime29]

I tried looking up these error codes and I’m getting conflicting results but I’m not a dealer tech. But it hints to me a possibly being a bad 12 volt battery. Since the cost of this repair is extremely high I would try to get another dealer to give you a second look. At least that’s what I would do.

100% this
I punched the error codes into Google to see what Gemini what spit out and it says they are Active Air Dam codes.
https://www.f150lightningforum.com/...ctive-air-dam-fault-message-in-the-ipc.22876/
https://www.f150lightningforum.com/...odes-p2c85-u0415-c0604-and-c0630-c1001.34036/

@Monica reamer A bad 12v is is listed as a potential cause for the errors. Double check that it's still good (auto parts stores will test it for free). It does seem odd if those error codes are accurate, that you were not able to charge. I also agree that you should ask for the battery health report. While not the same as a health test, an inexpensive OBD reader + phone app can give you an idea by looking at average voltage variation. There's plenty of threads here that talk about what values are considered out of range.

 

[flux capacitor]

2023 Lariat: I had 2 modules go out of spec one month after I bought it. I had tested charging at a Electrify America charge on a trip a few weeks after I bought it and a few days later pulling the truck out of the garage to put the trash out I get back in my truck to put it back in the garage and up comes the error. My brand new truck in the shop for 2 1/2 months to get it fixed. Since then no problems, but I have not made any more trips to need to charge at a charge station and only charge at home. I do not drive many miles a year mostly local. so by 2031 I hope batteries are a lot cheaper and/or new technology like Solid State Batteries.

 

[chl]

You left the truck sitting at home for some time and went on a cruise, and likely did not have the 12v battery on a maintainer, right?

That right there says to me 12v battery is the problem, not the HVB.

At least that is what Id suspect right off the bat.

If this is the original 12v battery, probably need to replace it.

TRY THAT FIRST.

Be sure they reset the BMS for the 12v battery too, some dealerships are not well versed in things.

Might want to try a different service dept/dealership.

 

[explosive0]

Good luck dealing with Ford. You're going to need it.

 

[TwentyTwentyThree]

There appears to be a low chance that we’ll see an update from OP

 

[chapba]

100% this
I punched the error codes into Google to see what Gemini what spit out and it says they are Active Air Dam codes.
https://www.f150lightningforum.com/...ctive-air-dam-fault-message-in-the-ipc.22876/
https://www.f150lightningforum.com/...odes-p2c85-u0415-c0604-and-c0630-c1001.34036/

@Monica reamer A bad 12v is is listed as a potential cause for the errors. Double check that it's still good (auto parts stores will test it for free). It does seem odd if those error codes are accurate, that you were not able to charge. I also agree that you should ask for the battery health report. While not the same as a health test, an inexpensive OBD reader + phone app can give you an idea by looking at average voltage variation. There's plenty of threads here that talk about what values are considered out of range.

sorry to be that guy but I have to ask which threads discuss the ranges? I searched for “average module voltage variation” and “average voltage variation” and only 4 threads came up with a few references to .01% being a good indicator of healthy modules. Is this a correct assumption or am I not seeing the correct threads?

 

[electricpig]

sorry to be that guy but I have to ask which threads discuss the ranges? I searched for “average module voltage variation” and “average voltage variation” and only 4 threads came up with a few references to .01% being a good indicator of healthy modules. Is this a correct assumption or am I not seeing the correct threads?

There have been threads where people have seen relatively large voltage variations prior to a module failure. It has been assumed a cell within a module was failing resulting in a high variation, until a certain threshold is reached (as determined by Ford) triggering an error for the module and shutdown.

 

[Zprime29]

sorry to be that guy but I have to ask which threads discuss the ranges? I searched for “average module voltage variation” and “average voltage variation” and only 4 threads came up with a few references to .01% being a good indicator of healthy modules. Is this a correct assumption or am I not seeing the correct threads?

https://www.f150lightningforum.com/...op-safely-now-fixed-post-24.26883/post-626357
Here's one example, I haven't looked at mine in a very long time. I should probably start tracking it as well. I've got another 4 years/45k miles of battery warranty so for the moment I'd only be inconvenienced for the time it's out of commission. Would be less of an inconvenience if I see it coming.

 

[chapba]

https://www.f150lightningforum.com/...op-safely-now-fixed-post-24.26883/post-626357
Here's one example, I haven't looked at mine in a very long time. I should probably start tracking it as well. I've got another 4 years/45k miles of battery warranty so for the moment I'd only be inconvenienced for the time it's out of commission. Would be less of an inconvenience if I see it coming.

awesome! Looks like a good indicator to keep track of but someone mentioned a cell/module report through FDRS is the more accurate picture? Thanks for the help! I need to learn/purchase FDRS

 

[Zprime29]

awesome! Looks like a good indicator to keep track of but someone mentioned a cell/module report through FDRS is the more accurate picture? Thanks for the help! I need to learn/purchase FDRS

Here's the main thread for FDRS: https://www.f150lightningforum.com/forum/threads/lightning-software-updates-using-fdrs.11029/

It's a long thread, hefty up front cost for the cable and power supply. I went a long stretch without updates and finally relented to buying a cable. But then I started getting updates again so I held off on the power supply. I haven't gotten the latest round of updates so I'm tempted again, but they jacked up the price for a FDRS license so much that I'm not sure it's worth it anymore.

 

[chapba]

Here's the main thread for FDRS: https://www.f150lightningforum.com/forum/threads/lightning-software-updates-using-fdrs.11029/

It's a long thread, hefty up front cost for the cable and power supply. I went a long stretch without updates and finally relented to buying a cable. But then I started getting updates again so I held off on the power supply. I haven't gotten the latest round of updates so I'm tempted again, but they jacked up the price for a FDRS license so much that I'm not sure it's worth it anymore.

yeah I have the cable and read some of that thread before but I will look through again. Thanks for the help!

 

[djwildstar]

My 2022 F150 with 113,000 miles [... PCM diagnostic trouble codes] C0630:00:66 and C0604:00:68. They are telling me I suddenly have 2 battery cells that need to be replaced at a cost of $11,000.,

I have some reservations about all this. Google suggests that DTC C0630:00:xx indicates that the active air dam is stuck or inoperative. Similarly, Google suggests DTC C0604:00:xx originates with the active air dam actuators. The normal approach would be to troubleshoot the air dam and replace the actuators if they're bad. Active air dame faults were definitely an issue for the 2022 Lightnings (and also for gas trucks in the 2021-2023 model years). For whatever reason, in the F-150 (both gas and electric), the active air dam is the responsibility of the powertrain control module (PCM). While battery problems will be presented as a power train fault, the codes for this are usually stored in the battery energy control module (BECM) rather than the PCM.

If nothing else, I'd want to see more documentation on why the dealership thinks that this truck needs 2 high-voltage battery modules to fix what appears to be an active air dam fault. If nothing else, the FDRS readout showing the battery problem.

Out of curiosity, has your '22 ever had the 12V battery replaced?

If not, it is quite possible that the PCM error codes are a side-effect of a low 12V battery. It is fairly common for a low 12V battery to cause all sorts of weird error codes to pop up. Have the 12V battery replaced with a new one, reset the 12V battery management system (BMS), clear the trouble codes, and see what happens. If the powertrain malfunction pops up again, take it for troubleshooting, ideally to a different dealership.

Specific to your questions:

1. Yes -- in general a problem with one or two (out of a total of 9) battery modules will result in reduced performance, reduced charging, and possibly total inoperability of the entire truck. A problem requiring replacement of two battery modules has happened before.
2. The entire battery pack charges and discharges as a unit, so a problem with one or two modules means reduced performance from the entire pack. To make a bad analogy, get a big flashlight that takes four D-size batteries; put in three good batteries and one dead one, and see how well the flashlight works.
3. This is the first out-of-warranty battery failure I'm aware of, but it is fairly common for a battery module failure to cause a powertrain malfunction message and require replacement of one or more battery modules.

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