2022 Pro ER Mass System Shutdown While Driving

[xveganxcowboyx]

My 2022 experienced repeated errors while driving last weekend (traction/stability control, cross traffic alert, blind spot alert, powertrain malfunction, etc) with total power cut and a warning to pull over safely. I found that power cycling the truck would get me about three minutes of drive time and all of most errors cleared, then the error would repeat and cut all power.

I thought the (apparently) original 12v battery might be on its way out so I replaced it today and reset the battery monitor. Unfortunately the fault continues and I'm at a loss. I can't see any obvious rodent damage at any visible wiring points. Coolant was a bit low so I topped it up, but that seems unrelated.

Maybe related: I gave it a hard flogging to see if it was a battery problem. I had 94% power to begin with, then up to 100% after a few miles (about 30*f). Regeneration did not register on the gauges. Brake coach said power was returned, but the brakes were hot and stinky, so I don't think any regeneration happened.

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[Maxx]

Maybe related: I gave it a hard flogging to see if it was a battery problem. I had 94% power to begin with, then up to 100% after a few miles (about 30*f). Regeneration did not register on the gauges. Brake coach said power was returned, but the brakes were hot and stinky, so I don't think any regeneration happened.

‘What was your SOC when this happened? Maybe regen is disabled at high SOC to protect the battery?

are the contacts on 12V battery clean and good?

what is 12V SOC reading?

 

[xveganxcowboyx]

HV battery was 70-80% when I noticed the regeneration issue.

12v battery contacts are clean with a good connection.

I can't see the 12v state of charge, but I added some charge after purchasing with a big charger which read fully charged, so I would assume relatively high.

 

[chl]

Sounds like it is all related to the 12V battery - wiring connections or control.

Are the connection clamps on the new battery good and tight?

You recalibrated the BMS, maybe repeat that process again.

Anything malfunctioning in the 12V system seems capable of causing multiple error messages from other posts I've seen here.

Get a forscan read and see what's going on.
---
One post said " The BMS was an inexpensive part. Once replaced by dealer.., all back to normal. "

https://www.f150lightningforum.com/...stions-for-the-gurus.31313/page-2#post-577623

 

[xveganxcowboyx]

Ok, so my thought of it being a 12V battery issue isn't crazy. (It's also winter in Minnesota and I drive it maybe twice a month, so that fits).

I previously read about the 12v BMS issue, but my truck has no open CSB or recalls that I can see (via app and Ford website). My part number is NL3T-10C652-BA, which isn't listed on the post I found, but the 652 matches the "bad" BMS more closely. Maybe I'll replace that too be safe and do a relearn.

I have the correct adapter and Forscan, but am new to it. Any tips on finding useful data? I ran some module tests, which turned up fine for the half dozen I tried. The dashboard function didn't get me any real data. I want to learn enough to enable a brake controller, but solving this reliability/safety issue is obviously a much bigger priority.

 

[chl]

Ok, so my thought of it being a 12V battery issue isn't crazy. (It's also winter in Minnesota and I drive it maybe twice a month, so that fits).

I previously read about the 12v BMS issue, but my truck has no open CSB or recalls that I can see (via app and Ford website). My part number is NL3T-10C652-BA, which isn't listed on the post I found, but the 652 matches the "bad" BMS more closely. Maybe I'll replace that too be safe and do a relearn.

I have the correct adapter and Forscan, but am new to it. Any tips on finding useful data? I ran some module tests, which turned up fine for the half dozen I tried. The dashboard function didn't get me any real data. I want to learn enough to enable a brake controller, but solving this reliability/safety issue is obviously a much bigger priority.

I am not adept with forscan either but there are a lot of forums folks who are, maybe they could pinpoint the faulty component?

When the 12v battery has issues or a bad component in the chain, power may not be supplied to things that are required for communication among the various components so errors can proliferate and cascade, from what I have read.

In a recent post a bad cabin heating element (the PTC) caused a general error message "Service vehicle soon." It took a trip to Ford for diagnostic to pinpoint it to the PTC.

On the other had, trouble with the HVB can also cause the trouble you have I'd guess.
The 12V system is interconnected to the DC-DC converter that charges the 12V battery and supplies the 12V components when the truck is on.

So if there is a problem with the HVB, it can manifest as trouble with the 12V system.
Trouble with the DC-DC converter as well.

If it's a HVB problem, you have the 8 year 100K warranty, if something else like the PTC maybe the 3yr warranty or extended coverage if you have it.

Good luck.

 

[TaxmanHog]

My part number is NL3T-10C652-BA, which isn't listed on the post I found, but the 652 matches the "bad" BMS more closely. Maybe I'll replace that too be safe and do a relearn.

Has the LVB BMS been changed yet?

 

[xveganxcowboyx]

I picked one up from the dealer today and plan to swap it this evening. I believe it has the original, but as per my post above, the part number is not listed as either the old or revised version in the thread detailing the differences.

 

[TaxmanHog]

Make sure to charge up the 12v while you have it disconnected.

Then, attach new BMS, do the relearn/reset process and let the truck 'idle' in drive ready mode for a couple hours, or do a long Level 2 charging session to ensure the LVB is indeed topped up.

Hopefully that clears up any faults, if not I'd take it in for a service review.

 

[chl]

Hope it was the BMS, there have been some that had to be replaced, fingers crossed!

 

[xveganxcowboyx]

I picked up a slow charger with a bit better parameters than my other yesterday and connected it, so it should be charged up. It's initial impression was the battery was at 55% SOC, but given the large load during awake mode I don't entirely trust that number.

I'll be sure to give it a couple hours in drive mode after replacement.

 

[chl]

I picked up a slow charger with a bit better parameters than my other yesterday and connected it, so it should be charged up. It's initial impression was the battery was at 55% SOC, but given the large load during awake mode I don't entirely trust that number.

I'll be sure to give it a couple hours in drive mode after replacement.

Be sure the charger negative connection is downstream of the BMS sensor or to a ground point and not on the negative terminal of the battery itself:

https://www.f150lightningforum.com/forum/threads/charging-12v-battery.16979/

PS: the charger should be one with an AGM mode as well.

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