Battery Pack MODULE Replacement: '22 Pro SR @ 62,000 miles

[Adventureboy]

curious which modules were replaced - I had 6&7 (not a joke Gen Aplha) so curious to know if there’s a consistent pattern

I am also curious how the trucks are being used. OP has towed about 1/2 of the miles, which may put additional stress on the battery modules compared to someone who doesn't and I'm wondering if there are higher failure rates on folks that tow more regularly with or without Max Tow option.

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[jefrank]

I am also curious how the trucks are being used. OP has towed about 1/2 of the miles, which may put additional stress on the battery modules compared to someone who doesn't and I'm wondering if there are higher failure rates on folks that tow more regularly with or without Max Tow option.

I don't tow often and it's just my utility trailer when I do, rarely charge away from home, charging at 48a at home (up from 24a for the first 30 months)... battery fault at 42k miles, 39 months.

 

[zakress]

I am also curious how the trucks are being used. OP has towed about 1/2 of the miles, which may put additional stress on the battery modules compared to someone who doesn't and I'm wondering if there are higher failure rates on folks that tow more regularly with or without Max Tow option.

Almost zero towing and the bed is used for mulch, gravel, camping equipment, and e-bikes. Mine is a dog transporter for most of the time.

 

[MotoGary]

Sorry about your truck issue. At least it didn't "break down" on you!

 

[RLXXI]

The high voltage battery and eDrive systems of your vehicle are covered by the Electric Vehicle Component coverage for eight years or 100,000 miles, whichever comes first. High voltage battery and eDrive components covered by this warranty include the high voltage battery assembly, Bussed Electrical Center (BEC), Battery Energy Control Module (BECM), on-board charger, Inverter System Controller (ISC), DC/DC converter, and eDrive. If a covered component requires replacement under the Electric Vehicle Component warranty, it may be replaced with a new, factory remanufactured, or factory refurbished component, at Ford’s discretion. Refurbished battery components selected for your vehicle will align with your vehicle’s age and mileage and meet Ford’s requirements and standards.

Any mention of "Powertrain" 5/60 is for ICE vehicles, (engine/trans/differentials)

 

[chl]

The high voltage battery and eDrive systems of your vehicle are covered by the Electric Vehicle Component coverage for eight years or 100,000 miles, whichever comes first. High voltage battery and eDrive components covered by this warranty include the high voltage battery assembly, Bussed Electrical Center (BEC), Battery Energy Control Module (BECM), on-board charger, Inverter System Controller (ISC), DC/DC converter, and eDrive. If a covered component requires replacement under the Electric Vehicle Component warranty, it may be replaced with a new, factory remanufactured, or factory refurbished component, at Ford’s discretion. Refurbished battery components selected for your vehicle will align with your vehicle’s age and mileage and meet Ford’s requirements and standards.

Any mention of "Powertrain" 5/60 is for ICE vehicles, (engine/trans/differentials)

Powertrain 5/60 is in the BEV warranty booklet I got when I got my 2023 Pro (attached).

However it covers multiple E-vehicles according to the title: "2023 Model Year Battery Electric Vehicle Warranty Guide (E-Transit, Mustang Mach-E, F-150 Lightning)"...


:...(1) Your vehicle’s Powertrain components are covered for five
years or 60,000 miles, whichever occurs first. The extended
Powertrain coverage applies to all components of the driveline
that are not specifically covered by the Electric Vehicle
Component warranty. Powertrain components that receive
warranty coverage for five years or 60,000 miles may include
gears, differential, shafts, fluid pumps, seals and gaskets,
bearings, mounts, drive shaft, retainers, supports, universal and
constant velocity joints.

(2) The high voltage battery and eDrive systems of your vehicle
are covered by the Electric Vehicle Component coverage for eight
years or 100,000 miles, whichever comes first. High voltage
battery and eDrive components covered by this warranty include
the high voltage battery assembly, Bussed Electrical Center
(BEC), Battery Energy Control Module (BECM), on-board
charger, Inverter System Controller (ISC), DC/DC converter, and
eDrive. If a covered component requires replacement under the
Electric Vehicle Component warranty, it may be replaced with a
new, factory remanufactured, or factory refurbished component,
at Ford’s discretion. Refurbished battery components selected
for your vehicle will align with your vehicle’s age and mileage and
meet Ford’s requirements and standards..."

 

[chl]

I am also curious how the trucks are being used. OP has towed about 1/2 of the miles, which may put additional stress on the battery modules compared to someone who doesn't and I'm wondering if there are higher failure rates on folks that tow more regularly with or without Max Tow option.

Yes I wonder if the OP had the tow package "MAX TRAILER TOW PACKAGE" with the extra cooling?
Even though I did not plan to do 'heavy' towing or a lot of towing, I thought the extra cooling would be helpful for battery longevity.

 

[RLXXI]

Powertrain 5/60 is in the BEV warranty booklet I got when I got my 2023 Pro (attached).

However it covers multiple E-vehicles according to the title: "2023 Model Year Battery Electric Vehicle Warranty Guide (E-Transit, Mustang Mach-E, F-150 Lightning)"...


:...(1) Your vehicle’s Powertrain components are covered for five
years or 60,000 miles, whichever occurs first. The extended
Powertrain coverage applies to all components of the driveline
that are not specifically covered by the Electric Vehicle
Component warranty. Powertrain components that receive
warranty coverage for five years or 60,000 miles may include
gears, differential, shafts, fluid pumps, seals and gaskets,
bearings, mounts, drive shaft, retainers, supports, universal and
constant velocity joints.

(2) The high voltage battery and eDrive systems of your vehicle
are covered by the Electric Vehicle Component coverage for eight
years or 100,000 miles, whichever comes first. High voltage
battery and eDrive components covered by this warranty include
the high voltage battery assembly, Bussed Electrical Center
(BEC), Battery Energy Control Module (BECM), on-board
charger, Inverter System Controller (ISC), DC/DC converter, and
eDrive. If a covered component requires replacement under the
Electric Vehicle Component warranty, it may be replaced with a
new, factory remanufactured, or factory refurbished component,
at Ford’s discretion. Refurbished battery components selected
for your vehicle will align with your vehicle’s age and mileage and
meet Ford’s requirements and standards..."

5/60 is ICE powertrain warranty. 8/100 for electric powertrain.

 

[chl]

5/60 is ICE powertrain warranty. 8/100 for electric powertrain.

Yes, I hear ya...

All I'm pointing out is this 5/60 language came from a BEV (battery electric vehicle) Warranty Guide from FORD - NOT from a ICE warranty guide.

I suppose we have seals and gasket, fluids, retainers?
I haven't looked at the E-transit or MAch-e, maybe they have some of the things mentioned...

Or maybe Ford just messed up and left that 5/60 stuff in from an old ICE guide?

Go figure.

 

[RLXXI]

Yes, I hear ya...

All I'm pointing out is this 5/60 language came from a BEV (battery electric vehicle) Warranty Guide from FORD - NOT from a ICE warranty guide.

I suppose we have seals and gasket, fluids, retainers?
I haven't looked at the E-transit or MAch-e, maybe they have some of the things mentioned...

Or maybe Ford just messed up and left that 5/60 stuff in from an old ICE guide?

Go figure.

Ford is known to blanket warranty info. In this case the topic being warranty salad. There are seals and oils (trans fluid) in use in both motors hence the oil filters on each. According to this wsm, the 25 motors use a trans type pan and filter.

 

[chl]

Ford is known to blanket warranty info. In this case the topic being warranty salad. There are seals and oils (trans fluid) in use in both motors hence the oil filters on each. According to this wsm, the 25 motors use a trans type pan and filter.

And 15 minutes later, you're hungry for more clarity...

 

[GoodSam]

replaced - I had 6&7 (not a joke Gen Aplha) so curious to know if there’s a consistent pattern

What was your mileage at HV battery modules replacement? Build month in 2022? See my tracking spreadsheet, mostly those folks posting in this forum, in my signature below. I think the replaced module numbers are spread evenly between the 9 units. for you, #6 & #7 would be less work because they are on top.

 

[MaintGrl]

The service writer allowed me to stand next to them and look over the pages of information about the truck... nice. While they have replaced a harder-to-replace MachE module, they had not done this with a LIGHTNING - although, the Lightning is probably an easier job, easier to get to the pack, etc.

I think the 'time' is mostly in the waiting:

- waiting for someone to schedule for the diagnosis of the issue
- waiting during the day-long, or multi-day, diagnosis
- finally receiving a call that Ford has approved the ordering of the new Replacement Module
- waiting several days/or even more if over the weekend, for the dealer to receive the module
- waiting for the tech's scheduled 'time' to start the process
... it's been a week and a half, so far...

I stopped by, in my wife's EV9, at the end of the day yesterday, to 'look' at my baby. She was in an open bay, right next to the Dealer's sales floor entry door, with no one around.
It looks like they've removed all the bolts from the Battery Pack cover, and those from the top of the Module crate... but, I couldn't tell if that means the new module has already been replaced, or not.

it looks like today is the day. maybe.

At least the FORD App allowed me to 'see' when they turned the truck ON, or moved it, etc., during the first so many days. Now it just tries and fails to connect to the server, which I take to mean that the 12v battery is detached, while under replacement.

Wow, seems like you "Lucked Out" with that dealer (Competent, intelligent) . Being able to photo some of the repair, looks like a keeper! I hope I'm as Lucky when my day comes...

 

[chl]

What was your mileage at HV battery modules replacement? Build month in 2022? See my tracking spreadsheet, mostly those folks posting in this forum, in my signature below. I think the replaced module numbers are spread evenly between the 9 units. for you, #6 & #7 would be less work because they are on top.

Does your data indicate an connection between the module failure and the density of cells, i.e., 55 cells vs 40 cells?

Or SR vs ER?

The 9 SR battery modules all have 40 cells, the ER has 8 modules with 55 cells and one with 40 (module 9 I believe).

I have seen at least one report of a module #9 failure.

 

[hturnerfamily]

Pro Model: SR ~100kwh battery pack
Build date 7 13 22
delivered 8 23 22
62,100 miles at time of charging error

no response from the dealer, yet, although, as my original photos show, they had the battery pack dropped... the dealer 'service writer' person can't tell me anything, as she's never had anything to do with 'battery replacement', or probably much with ANY electric vehicle... and she doesn't have the experience to even know where the techs are along on the process... my app no longer connects, so I can't see anything, either... over two weeks now. She said mid-afternoon yesterday that the tech and the 'manager' were at a meeting, and would probably have it buttoned up by the end of the day, and the manager would call when he returned: he never did. they never did. Nothing. Crickets.

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