Charging error (All 5 segments turn RED) HVB Module failure

[chl]

I guess they figured that out:

"Good morning David. The becm has been installed on the vehicle. After charging the vehicle and retesting we found 2 high voltage battery cells have also gone bad. I'm currently waiting for the parts department to give me information on the availability of the cells. I will be in touch later on today with more information."

Damn, sorry, this is one time I wish I hadn't been right.

I think any electrical engineer worth their weight in chalk board dust (like me, lol), would have had the same suspicion.

I don't blame the techs, car techs just follow a process step by step based on diagnostic codes without seeing the big picture which they aren't educated to see.

But the Ford BEV folks should know what the symptoms of bad cells is and improve the training.

So sorry, but once the bad cells are replaced, things should be fine...fingers crossed!

Good luck!

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[chl]

Latest
"The part is covered under the electric warranty of the vehicle. I expect to have the part here tomorrow. You also need tires for the vehicle. I'm going to text you the quote for tires in the next minute or two."


Tires:

"Recommended service
$1,283.47
MOUNT AND BALANCE 4: MOUNT AND BALANCE 4 TIRES"

I requested manufacturer and model information about the tires

OMG!
WTF happened to your tires?
That's a pretty steep quote! Must be premium tires and premium labor per hour costs?

 

[Heliian]

That's a pretty steep quote!

LOL, you obviously haven't bought truck tires in the last 10 years. That quote is pretty good.

 

[chl]

LOL, you obviously haven't bought truck tires in the last 10 years. That quote is pretty good.

Really?

Damn!

It's shocking to my system!

 

[chl]

LOL, you obviously haven't bought truck tires in the last 10 years. That quote is pretty good.

Yes, you're right.

I just checked my records and the last tires I bought for my 2001 Ranger in 2014 cost me about $225 for 2 front tires installed with road hazard insurance to boot!

OMG, now that's tire inflation!

Speaking of which...

 

[doggod]

I have been waiting 3 months for a new charging port on my 2023. the 2 black rubber protectors on the CCS portion of the port somehow came up missing. most likely stuck in some CCS charger plug. this is a problem because you can get electrocuted by touching both at the same time. can still charge at home on AC.
also USB ports failed after last recall. hopefully they will have the parts when I get the new charger port.

 

[chl]

I have been waiting 3 months for a new charging port on my 2023. the 2 black rubber protectors on the CCS portion of the port somehow came up missing. most likely stuck in some CCS charger plug. this is a problem because you can get electrocuted by touching both at the same time. can still charge at home on AC.
also USB ports failed after last recall. hopefully they will have the parts when I get the new charger port.

I believe the two DC pins are only energized when DC charging has been initiated.
Is that what you are referring to?
----
"When a CCS1 connector is plugged into a DC charging station, the two DC pins are energized, enabling the transfer of DC power to the vehicle's battery..."

"To ensure the safety of the charging process, the CCS1 has a locking mechanism that prevents the connector from being accidentally disconnected during charging. This is an important feature that reduces the risk of damage to the charging equipment and improves safety for both the driver and the vehicle. "
----
Maybe you mean the locking mechanism isn't working? That would be a serious problem - arcing - if the plug were removed during charging?

 

[LightningJB]

OMG!
WTF happened to your tires?
That's a pretty steep quote! Must be premium tires and premium labor per hour costs?

45k on the original rubber. Quoted tires are the Michelin defenders. The quote was close enough to local tire dealers that I was comfortable. Tread was down enough to be warned about at annual MA inspection.

parts are due in next Thursday. Wondering if my rental shouldn't be covered by Ford

 

[flyct]

45k on the original rubber. Quoted tires are the Michelin defenders. The quote was close enough to local tire dealers that I was comfortable. Tread was down enough to be warned about at annual MA inspection.

parts are due in next Thursday. Wondering if my rental shouldn't be covered by Ford

Ford might cover the rental if either
1- You have a Ford Extended Warranty with 1st day rental coverage that you paid for
2- They agreed to it front
3- You get the BEV team to agree to it.

My recent Lightning purchase was at a local dealership that provides FREE loaners for only customer's that bought vehicles from them. They picked up my Lightning and delivered a Brand New 2025 Expedition last week when I needed service. I was only responsible to give it back with the same Full Fuel as it was delivered with.

 

[doggod]

finally got the charger port at dealer took truck in yesterday. said it would take 3 hours. took car in at 12pm came back at 4:30pm and they said it will take at least another 4 hours. so we had to leave it and they will call on Monday when finished. at least they offered to bring it to our house, which I 83 miles away.

I was told those pins are for DCFC top portion is for AC and communication. however I did not design or research this just took their word.

 

[TaxmanHog]

I was told those pins are for DCFC top portion is for AC and communication. however I did not design or research this just took their word.

That is true....

 

[Piquette]

Sounds like they are having to reprogram parts of the charging system to accommodate the new charging port parts. This can sometimes take many hours of a tech’s time.

 

[chl]

finally got the charger port at dealer took truck in yesterday. said it would take 3 hours. took car in at 12pm came back at 4:30pm and they said it will take at least another 4 hours. so we had to leave it and they will call on Monday when finished. at least they offered to bring it to our house, which I 83 miles away.

I was told those pins are for DCFC top portion is for AC and communication. however I did not design or research this just took their word.

Yes the pins on the truck are for DC charging he battery directly, but they are NOT energized (connected to the battery) unless you are hooked up to a Fast DC charger when internal contacts are engaged to make the connection under control of the on-board software system designed with electrical safety in mind.

So, as far as I know, they are not a danger of shock unless you somehow touched them during a Fast DC charging cycle - which would be hard to do since the plug or adapter is supposed to lock to prevent premature withdrawal and the arcing that could result, and the pins are recessed on the truck.

The charging software communication protocol handles the requests and responses for the on-off of the DC fast charging connection, and there is a button you can push to end the charging as well (next to the CCS1 plug socket).

I read about a couple fast charger shock incidents, very rare,, but I believe they were when a maintenance person was working on them and made a fatal mistake - electricity can be unforgiving.

Obviously if the charge station looks like it has been damaged don't use it. But battery fires during fast charging are more of a risk than electric shock, and they are rare as well. And most of those incidents were Tesla's.

https://www.researchgate.net/figure...ctric-vehicles-in-recent-years_tbl1_355228230

Of course, not having the truck DC pins covered could lead to other problems eventually if water got down in there and corroded them.

The one thing never to touch would be the pins on the DC charger itself!

I there was a fault they could be energized before plugging in to the vehicle receptacle - unlikely but...

 

[doggod]

finally got my truck back only took them 5 days to replace the port. replaced my USB ports in front, they stopped working. I also see the replaced the battery tray? and recharged the AC?

not able to touch the DCFC pins on charger when they are powered up as they have to be plugged in to activate and unable to unplug without being powered off.

Dealer said it could lead to plug not fitting properly. to me that means could short out and cause fire

 

[Heliian]

read about a couple fast charger shock incidents, very rare,,

I have never heard of anyone being shocked by a dcfc but anything is possible. If you know of any links, I'd love to read.

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