Battery Overheat During DC Fast Charging

[K6CCC]

I have seen the gauge about the normal middle lime, but no where near that much above the line this summer. During the hot summer weather, I have several times charged in 105+ temps. Several of those had the AC keeping the cabin cool and a couple did not. Almost always in those conditions I see the gauge move a little.
My truck does not have the Max Towing package and I normally drive in "normal" mode. I have observed that switching to either Sport or Tow/Haul mode helps speed up cooling it back to normal once I start driving.

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[TaxmanHog]

Thank you all for the responses. I was driving in normal mode, not towing. AC was set to 70. Temple was the first charge of the day. Fortunately, I do have the extended warranty, but I am going to contest the copay on it as they did not resolve the issue when I took it in back in June for the same issue.

Do you hear any repetitive clicking noises near the frunk??

I wonder if the diverter valve is malfunctioning or stuck in a position that's preventing the chiller from extracting heat from the coolant loop!

#17 & #24

https://www.f150lightningforum.com/...in-thermal-management-system-pictorial.34883/

 

[Joneii]

This is not just a problem with your truck. It has been happening for a while. See the discussion in this thread:

“Should my F-150 lightning battery ever be above the middle temperature mark”

I dealt with several dealerships over the course of at least a year. They changed cooling valves, my charge port, updated software, replaced a battery module or two and the problem still exists. As I am now at 111,000 miles my warranty no longer gets me free work on this problem. Therefore, I’ve now accepted that this is the new normal for my truck and I just plan on the second and third charges of the day on a road trip will be slower.

 

[GoodSam]

switching to either Sport or Tow/Haul mode helps speed up cooling it back to normal once I start driving

Was going to Sport mode also good to use before getting to the DCFC to extra cooling of the battery pack?

 

[K6CCC]

Was going to Sport mode also good to use before getting to the DCFC to extra cooling of the battery pack?

I don't have any data, but likely yes.

 

[electricpig]

This is my recollection as well. It's a sad truth that the customer has to educate the provider, but here we are.

IMHO, in many cases it's the dealer trying to double dip on warranty work. Charge.Ford.for the warranty work, charge the customer too. After all we all know how honest the vast majority of dealerships are these days.

 

[Firn]

Was going to Sport mode also good to use before getting to the DCFC to extra cooling of the battery pack?

Yes

Normal mode lets the battery get up over 100 degrees before cooling it, sport and tow both try to get the battery to the mid 80s.

It will lower your efficiency however.

 

[blazetke]

8/26/26 Update

Just off the phone with the dealer. Dealer states that Ford has advised them that the truck is not designed to DC Fast Charge in a ready state with Climate Control on. That all DC Fast Charging must be done with the vehicle off.

They have told me that if I can prove the vehicle overheats while fast charging with it off and no climate control active, that I can bring it back in.

I have asked for this in writing and will provide a copy if they actually do it.

I do have a case with BEV open.

 

[JayF]

Please do get it in writing. Not being able to run climate control while charging is absolutely nuts -- especially in extremely hot weather.

 

[halfbakedenchilada]

8/26/26 Update

Just off the phone with the dealer. Dealer states that Ford has advised them that the truck is not designed to DC Fast Charge in a ready state with Climate Control on. That all DC Fast Charging must be done with the vehicle off.

They have told me that if I can prove the vehicle overheats while fast charging with it off and no climate control active, that I can bring it back in.

I have asked for this in writing and will provide a copy if they actually do it.

I do have a case with BEV open.

The technical term for this is "horseshit." I DCFC in 100 degree weather all of the time, and in 110 degree weather not infrequently, and this never happens to me. The battery gets to 111-113 max, even with the AC on. In my experience the thermals are pretty good on this battery.

 

[RickLightning]

8/26/26 Update

Just off the phone with the dealer. Dealer states that Ford has advised them that the truck is not designed to DC Fast Charge in a ready state with Climate Control on. That all DC Fast Charging must be done with the vehicle off.

They have told me that if I can prove the vehicle overheats while fast charging with it off and no climate control active, that I can bring it back in.

I have asked for this in writing and will provide a copy if they actually do it.

I do have a case with BEV open.

BULLSHIT.

@Ford Motor Company, someone needs to be fired or demoted at corporate for spewing crap like this.

OPEN MANUAL. Says NOTHING about turning off vehicle, BECAUSE IT'S HORSESHIT.

 

[TaxmanHog]

@Ford Motor Company you need to have a regional service rep provide remedial training ASAP at this dealership!

 

[K6CCC]

Just off the phone with the dealer. Dealer states that Ford has advised them that the truck is not designed to DC Fast Charge in a ready state with Climate Control on. That all DC Fast Charging must be done with the vehicle off.

Be interesting to see what the BEV team says about that.
I see several other people have responded similarly...

 

[Zprime29]

8/26/26 Update

Just off the phone with the dealer. Dealer states that Ford has advised them that the truck is not designed to DC Fast Charge in a ready state with Climate Control on. That all DC Fast Charging must be done with the vehicle off.

They have told me that if I can prove the vehicle overheats while fast charging with it off and no climate control active, that I can bring it back in.

I have asked for this in writing and will provide a copy if they actually do it.

I do have a case with BEV open.

You probably kept your cool better than I would have. Unbelievable....

 

[blazetke]

Plot thickens…Just off the phone with BEV and they provided me a transcript of the interaction with the Dealer.
It appears what the Dealer’s Service Advisor has told me is false. I have placed a call for the Dealer Service Director to call me. Unfortunately, I am out of town on business until Friday PM and will not be able to pick up my truck until then.
I hate integrity checking someone, but in this instance, it’s indisputable.

…on a separate note, I love how passionate this group is in calling out the bs that I’m dealing with. Thank you!

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