2023 Lightning Lariat dead, backordered parts...

[chl]

Not a 12v battery junction box as I read it, but a HV junction box.

From what I have read on this forum, the HV battery is 9 modules which vary among the SR, ER and Flash capacity batteries:

480 cells = 131 kwh battery in the ER (8 x 55 + 1 x 40) or 96 series groups of 5 parallel cells

450 cells = 123 kwh battery in the Flash (6 x 55 + 3 x 40) or 90 series groups of 5 parallel cells

360 cells = 98 kwh battery in the SR (9 x 40) or 90 series groups of 4 parallel cells

They all have 9 modules and the 9 modules all take up the same physical space in the truck.
Also, the SR and Flash have one 11kW charger, while the ER has two 9.6kW chargers.

So they are replacing 2 modules of the 9, number 8 and number 9 modules.
They are also replacing an HV junction box.

I wonder if the failed modules are 55 cell or 40 cell or one of each?
And what caused the junction box failure?

FYI:

Here is a video about HV junction boxes:

This is a Lightning battery explanation (breakdown) video:

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[GoodSam]

And what caused the junction box failure?

I wonder if it really is a fuse that detected a cell short, hopefully to prevent a fire like the Safety Recall 25s18 is about. But maybe, on turning on the truck, the positive contactor (solid state?) just fails, then the cell fails in the modules were just on edge enough to be detected by the dealer diagnosis as bad.

I think dealers are (A) short staffed for Techs and (B) take too long to get into the work, (C) parts ordering for warranties takes extra steps, and (D) Ford delivery systems are not efficient.

 

[jetfixr1]

I wonder if it really is a fuse that detected a cell short, hopefully to prevent a fire like the Safety Recall 25s18 is about. But maybe, on turning on the truck, the positive contactor (solid state?) just fails, then the cell fails in the modules were just on edge enough to be detected by the dealer diagnosis as bad.

I think dealers are (A) short staffed for Techs and (B) take too long to get into the work, (C) parts ordering for warranties takes extra steps, and (D) Ford delivery systems are not efficient.

I hope the new announcement fixes this. In theory: less parts overall, majority of parts in common across all vehicles and technician training is one and done since all vehicles are the same.

 

[TaxmanHog]

But maybe, on turning on the truck, the positive contactor (solid state?)

The contactors are electromechanical solenoids

 

[chl]

I wonder if it really is a fuse that detected a cell short, hopefully to prevent a fire like the Safety Recall 25s18 is about. But maybe, on turning on the truck, the positive contactor (solid state?) just fails, then the cell fails in the modules were just on edge enough to be detected by the dealer diagnosis as bad.

I think dealers are (A) short staffed for Techs and (B) take too long to get into the work, (C) parts ordering for warranties takes extra steps, and (D) Ford delivery systems are not efficient.

Yes.
And battery failures like this are worrisome.

Fast charging and charging to 95% and above puts extra stress on the HV battery, but these batteries are suppose to be made to handle that otherwise no long trips are practical or safe.

A lot of possibilities for the junction box replacement, fuses contactor/solenoid, capacitors, etc.

Both a junction box replacement and 2 battery modules replacement would seem to indicate to me that perhaps the junction box blew a fuse due to an overcurrent or short circuit situation in the battery. The fuse blowing would disconnect the battery connection as a safety measure.

A short circuit in an EV HV battery is obviously a dangerous situation that could lead to a battery fire.

The good news is the junction box fuse blowing, if that's what it was, may have headed off a potential disaster.

The OP might ask for a detailed diagnosis printout which could enlighten us all about what happened.

 

[jjupi91897]

Here's a fun story for ya'll....

Spent several weeks planning a southern Colorado road trip from my town (Fort Collins) with my family of four. Determined based on the extended range battery, planned itinerary and distance between high speed chargers that we would be able to do the trip in the Lightning (1.5 years old, ~20k miles). Absolutely zero issues the entire trip until our 2nd to last day on the road. Spent the night in Durango, woke up (July 1), topped on the charge to 95% before heading north on 550 (the Million Dollar highway) en-route to Telluride via a stop in Orary for lunch. Made a quick pit stop at Purgatory Resort to get a little extra juice before heading up the pass. Stopped at the Molas pass overlook to take some pictures, got back in the vehicle and when I went to start it the dash alerted "Safely pull over!" and would not start. Luckily I had 1 bar of cell service and was able to call Ford Roadside Assistance. 2.5 hours later the tow truck arrived and brought us back to Durango Ford. Got a hotel for the night in Durango only to find out there are no one-way car rentals in the town to get us back to Fort Collins. Grabbed an Uber to Durango Ford the next morning and hung around for about 3 hours until the service advisor finally told me that they likely would not have a diagnosis and definitely not have it fixed that day. My crew had to be back in Fort Collins the following day so the only option was 4-one way tickets on United at $414 a piece, then a $110 Uber home from the airport. Once I got home I contacted Fort Custom Service and they opened a case for me, stating what others on this board have also stated, they would cover a rental for up to $60 / day for 10 days. They also stated that I could submit all of my receipts (i.e. airfare, $600 airbnb in Telluride I was unable to get to, Uber rides, etc.) that would be reviewed for consideration AFTER my vehicle is repaired and returned to me.

So, here we are, 5 weeks after the truck broke down, it is ~400 miles away from me still in the shop waiting on backordered parts with not ETA. Oh yeah - one more thing - as we were on a road trip we had some food in a cooler in the bed (have a cap on the bed). Obviously we couldn't fly with a cooler or several other things we had to leave behind in the vehicle. At one point a few weeks ago I thought, oh there's got to be some pretty spoiled food in the bed of that truck, I should ask Durango Ford if they can assist getting rid of the perishables. So I called the service advisor at Durango Ford:

Me: Also, odd question, but at this point I've got some pretty nasty food in the back of the truck. Might need some assistance cleaning it out.
Ford Service Advisor: No, no, that shouldn't be a problem any more
Me: Oh great, you already cleaned it out?
Ford Service Advisor: No, a bear actually broke into your truck in the lot and ate the food that was in the back, looked like some chocolate covered raspberries and some other tasty snacks....

So, now - in addition to making my monthly car payments and insurance payments, I am paying out of pocket for a rental (oh, has to be a Ford and those aren't always easy to come by), and opened an insurance claim for the bear incident.

WTF, Ford?!

Also, fyi - the current work order for the warranty work on the truck is at $18k!

I've contacted some lemon law attorneys, but have seen folks mentioning Ford buy-backs. Any other advice, or at the least other fun stories like this?

Everytime I take a long trip with my Lariat ER, I think about your post. Scarey stuff; although, I have had no problem with 50K miles logged.

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