Harvest Program 25H02

[adoublee]

For those included in this campaign:

The 8-year/100,000-mile warranty covers repairs or replacements for battery defects. If the campaign’s harvested modules had latent flaws (e.g., leading to gradual degradation), replacing them now could prevent a future failure that would qualify for a full pack replacement under warranty. Instead, you get a partial fix early, which might save you downtime later but could mean you don't get the "full" benefit of a complete new pack if issues had escalated.

Sponsored

 

[xwing]

I also got the letter. I'm really hesitant to have my dealer mess with my truck. I subscribe heavily toward the if its not broke, lets not fix it camp. I had it back 3 times for the complimentary steering wheel heater. It should have been obvious as to what was needed, but they needed it first to see what parts needed ordering. Second trip was to install the ordered parts. As a result, all the buttons on the left side of the steering wheel stopped working. Third trip was to fix that. It turns out they ordered the wrong parts that caused the problem even though trip one was to verify parts needed.

I'm leaning toward the if its not broke, don't fix it category. I'm already in the early adopter program, so I'm doing my part for software testing. (Still waiting for a way to control walk away locks. I do like the feature, would just like to have the ability to control it.)

If Ford were willing to offer some incentives for experimenting on my truck, that might be different. I agree that 8 year 100k warranty should cover any problems down the road. I also like the idea of having new parts, but there is a lot of risk to doing that. Extending out the warranty further could help.

Ironically, my truck is at the dealer now because it won't AC charge if the charge amperage is above 35 amps. They have diagnosed a bad charge controller and the parts should be in on Monday. I will ask them about this program when my truck is ready.

 

[electricpig]

Not getting in the argument above. Plus I have not gotten a letter. With that said, I would likely pass, and I'm a fairly alteristic person. I see significant risks, and little to no reward. Full new battery pack, I probably would do it. Ie. Significant reward for your time and trouble. But as it is, could be weeks without your truck that Fo d won't pay for etc. If this is really about getting ahead of potential failure, then Ford needs to come clean about it, and not some PR BS. I've had many instances to drive the If it ain't broke, don't fix it! Into my being.

 

[Lytning]

In my opinion, mixing 2 to 3 year old modules with new modules in the same battery pack can't be a good thing.

 

[RocketGhost]

In my opinion, mixing 2 to 3 year old modules with new modules in the same battery pack can't be a good thing.

The truck self-balances the modules, and I suspect the dealer diagnostic software advices the technician whether a single module replacement is acceptable. So far real-world data on degradation in our trucks indicates that it is very minimal which suggests that a 2 or 3 year old module is not much different than a new one.

Ford designed the batteries to have individually replaceable modules specifically for serviceability.

Personally I'd take a new module for free even if the benefit is small.

One thing I don't think that's clear from this campaign is whether it's strictly for research or if Ford thinks there's a potential module failure down the road in those trucks. Or maybe they're just not sure and want to dig into the modules to find out.

 

[mam0032]

I got the letter. I called my local dealership and the guy acted like he'd never heard the term "harvest program" before. After looking up my truck he says, "it's a recall". I understand the hesitation, I truly hate taking my truck to the dealer.

 

[adoublee]

Do it or don't do it it's your truck it's your call.

End the pissing in each other's corn flakes

Maybe with your sway as Moderator you can help get @Ford Motor Company to advise the forum if this is in practicality a repair situation or a donation request? I see they are active elsewhere in the forum.

 

[RickLightning]

I got the letter. I called my local dealership and the guy acted like he'd never heard the term "harvest program" before. After looking up my truck he says, "it's a recall". I understand the hesitation, I truly hate taking my truck to the dealer.

It is NOT a recall.

Recalls are safety-related and mandated by NHTSA. It is a voluntary program.

My 2022, as well as others here, had some modules fail and get replaced. My battery SOH, measured last week, after 16,000 miles and over 3 years from production (bought May 2023) is 100%. My dealership's tech is experienced.

IMO, the letter to the customer should emphasize that it is a voluntary program, with a comparable rental provided, and some form of compensation for the inconvenience.

 

[scoobybri]

Below is the NHTSA chronology of events that have led to the harvest program. They are calling it a recall in their report. Looks like there have been 5 vehicle fires that may be related to a battery manufacturing defect that could be present in batteries built between Jan 2022 and April 2023. SK determined that there was a miscalibration on 8 stacker machines that could lead to a cathode shift (which may cause a short and/or fire.) Since 4 of the 5 fires destroyed the batteries, Ford could not conduct the research to verify that these trucks had the battery defect. It looks like Ford is looking for a representative field sample across trucks with batteries made during that time period to determine if the cathode shift is present in enough batteries to issue a full recall. I'm curious if this issue may be limited to specific sized/shaped modules that are tied to the specific production machinery that was miscalibrated or if all modules have the potential cathode problem. If it is all modules, we may see full battery packs being replaced soon.

Although my inclination is to leave well enough alone, whether I would participate in the harvest program would be defined by a. Proper compensation b. an offer to extend my battery warranty to include problems that may arise from the replacement after the 8 years/100k miles, and c. if I trust my dealer to be able to do the job correctly.

Here is the text from the NHTSA chronology report...

Ford Motor Company (Ford) Recall No. 25S18 Chronology

CERTAIN 2022-2024 FORD F-150 BEV – BATTERY FIRES

Date of Submission: February 28, 2025

Chronology of Defect / Noncompliance Determination

Provide the chronology of events leading up to the defect decision or test data for the
noncompliance decision.

On October 17, 2024, an issue pertaining to a 2022 model year Ford F-150 Battery Electric
Vehicle (BEV) fire was brought to Ford’s Critical Concern Review Group (CCRG) for review
after Ford learned of the incident on October 9, 2024.

On November 21, 2024, two additional fires, involving a 2022 MY F-150 BEV and 2023 MY F-
150 BEV, were reported to Ford and CCRG opened a new investigation to more broadly
investigate claims of 2022-2023 model year Ford F-150 BEV fires with potential origination
within the high voltage battery pack. No physical samples from the vehicles were available for engineering evaluation at that time.

From December 2024 to January 2025, the CCRG investigation analyzed connected vehicle
data and supplier cell manufacturing history to explore a potential connection between the
vehicles involved in the fires.

On January 3, 2025, Ford received a fourth report of a fire involving a 2022 model year Ford F-150 BEV. On January 10, 2025, Ford Engineering received a battery array that had been replaced in one of the affected vehicles prior to the fire event.

From January 2025 to February 2025, Ford conducted teardown analysis on this battery array and continued this detailed review
of the supplier's manufacturing process.
On January 24, 2025, while this teardown analysis and review was ongoing, Ford’s Field Review Committee authorized Harvest Program 25H02 to obtain additional physical samples from the field for in-depth evaluation and root cause analysis to facilitate further testing and understanding of root cause.

On February 2, 2025, based on the teardown analysis on the returned array, Ford identified
evidence of misaligned electrodes in the high voltage battery cells. The supplier also identified evidence of cathode shift on eight stacker machines between two production lines based on a review of historical data for cells manufactured between January 3, 2022 and April 1, 2023. This manufacturing concern resulted in overlap that did not meet the supplier’s design requirement.
Some of the cells in the vehicles that experienced fires were built in this timeframe.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire that is under investigation.

On February 21, 2025, Ford’s Field Review Committee reviewed the concern and approved a field action.
Ford is not aware of any claims of crash related to this concern. Ford is aware of one claim of
injury and five reports of vehicle fire that may be related to this concern and are under further
investigation.

 

[RickLightning]

Interesting that the Ford document never says the word Recall, yet the NHTSA site does.

It will be very interesting to see if this leads to a widespread issue.

 

[Lytning]

Below is the NHTSA chronology of events that have led to the harvest program. They are calling it a recall in their report. Looks like there have been 5 vehicle fires that may be related to a battery manufacturing defect that could be present in batteries built between Jan 2022 and April 2023. SK determined that there was a miscalibration on 8 stacker machines that could lead to a cathode shift (which may cause a short and/or fire.) Since 4 of the 5 fires destroyed the batteries, Ford could not conduct the research to verify that these trucks had the battery defect. It looks like Ford is looking for a representative field sample across trucks with batteries made during that time period to determine if the cathode shift is present in enough batteries to issue a full recall. I'm curious if this issue may be limited to specific sized/shaped modules that are tied to the specific production machinery that was miscalibrated or if all modules have the potential cathode problem. If it is all modules, we may see full battery packs being replaced soon.

Although my inclination is to leave well enough alone, whether I would participate in the harvest program would be defined by a. Proper compensation b. an offer to extend my battery warranty to include problems that may arise from the replacement after the 8 years/100k miles, and c. if I trust my dealer to be able to do the job correctly.

Here is the text from the NHTSA chronology report...

Ford Motor Company (Ford) Recall No. 25S18 Chronology

CERTAIN 2022-2024 FORD F-150 BEV – BATTERY FIRES

Date of Submission: February 28, 2025

Chronology of Defect / Noncompliance Determination

Provide the chronology of events leading up to the defect decision or test data for the
noncompliance decision.

On October 17, 2024, an issue pertaining to a 2022 model year Ford F-150 Battery Electric
Vehicle (BEV) fire was brought to Ford’s Critical Concern Review Group (CCRG) for review
after Ford learned of the incident on October 9, 2024.

On November 21, 2024, two additional fires, involving a 2022 MY F-150 BEV and 2023 MY F-
150 BEV, were reported to Ford and CCRG opened a new investigation to more broadly
investigate claims of 2022-2023 model year Ford F-150 BEV fires with potential origination
within the high voltage battery pack. No physical samples from the vehicles were available for engineering evaluation at that time.

From December 2024 to January 2025, the CCRG investigation analyzed connected vehicle
data and supplier cell manufacturing history to explore a potential connection between the
vehicles involved in the fires.

On January 3, 2025, Ford received a fourth report of a fire involving a 2022 model year Ford F-150 BEV. On January 10, 2025, Ford Engineering received a battery array that had been replaced in one of the affected vehicles prior to the fire event.

From January 2025 to February 2025, Ford conducted teardown analysis on this battery array and continued this detailed review
of the supplier's manufacturing process.
On January 24, 2025, while this teardown analysis and review was ongoing, Ford’s Field Review Committee authorized Harvest Program 25H02 to obtain additional physical samples from the field for in-depth evaluation and root cause analysis to facilitate further testing and understanding of root cause.

On February 2, 2025, based on the teardown analysis on the returned array, Ford identified
evidence of misaligned electrodes in the high voltage battery cells. The supplier also identified evidence of cathode shift on eight stacker machines between two production lines based on a review of historical data for cells manufactured between January 3, 2022 and April 1, 2023. This manufacturing concern resulted in overlap that did not meet the supplier’s design requirement.
Some of the cells in the vehicles that experienced fires were built in this timeframe.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire that is under investigation.

On February 21, 2025, Ford’s Field Review Committee reviewed the concern and approved a field action.
Ford is not aware of any claims of crash related to this concern. Ford is aware of one claim of
injury and five reports of vehicle fire that may be related to this concern and are under further
investigation.

Thank you for the detailed technical information! It would be nice to know if this cathode shift issue is also related to the defective modules requiring replacement in "4%" of mostly 2022 Lightnings.

 

[TaxmanHog]

Below is the NHTSA chronology of events that have led to the harvest program. They are calling it a recall in their report.

Related threads:

Safety Program: 25S18 aka 25V131: HV Battery Electrode Misalignment Discussion

NHTSA 25V131 aka Recall 25s18: certain 2022-2024 F-150 Lightning – supplier manufacturing defect in high voltage battery cells

Parts are in for Recall 25V131 aka 25s18, Internal short circuit in High Voltage battery.

 

[RickLightning]

I believe the 4% of bad 2022 - 2023 modules did not result in a formal recall, or even CSP. Ford just reached out - or the truck had a failure, like mine.

 

[GoodSam]

Below is the NHTSA chronology of events that have led to the harvest program. They are calling it a recall in their report. Looks like there have been 5 vehicle fires that may be related to a battery manufacturing defect that could be present in batteries built between Jan 2022 and April 2023. SK determined that there was a miscalibration on 8 stacker machines that could lead to a cathode shift (which may cause a short and/or fire.) Since 4 of the 5 fires destroyed the batteries, Ford could not conduct the research to verify that these trucks had the battery defect. It looks like Ford is looking for a representative field sample across trucks with batteries made during that time period to determine if the cathode shift is present in enough batteries to issue a full recall. I'm curious if this issue may be limited to specific sized/shaped modules that are tied to the specific production machinery that was miscalibrated or if all modules have the potential cathode problem. If it is all modules, we may see full battery packs being replaced soon.

Although my inclination is to leave well enough alone, whether I would participate in the harvest program would be defined by a. Proper compensation b. an offer to extend my battery warranty to include problems that may arise from the replacement after the 8 years/100k miles, and c. if I trust my dealer to be able to do the job correctly.

Here is the text from the NHTSA chronology report...

Ford Motor Company (Ford) Recall No. 25S18 Chronology

CERTAIN 2022-2024 FORD F-150 BEV – BATTERY FIRES

Date of Submission: February 28, 2025

Chronology of Defect / Noncompliance Determination

Provide the chronology of events leading up to the defect decision or test data for the
noncompliance decision.

On October 17, 2024, an issue pertaining to a 2022 model year Ford F-150 Battery Electric
Vehicle (BEV) fire was brought to Ford’s Critical Concern Review Group (CCRG) for review
after Ford learned of the incident on October 9, 2024.

On November 21, 2024, two additional fires, involving a 2022 MY F-150 BEV and 2023 MY F-
150 BEV, were reported to Ford and CCRG opened a new investigation to more broadly
investigate claims of 2022-2023 model year Ford F-150 BEV fires with potential origination
within the high voltage battery pack. No physical samples from the vehicles were available for engineering evaluation at that time.

From December 2024 to January 2025, the CCRG investigation analyzed connected vehicle
data and supplier cell manufacturing history to explore a potential connection between the
vehicles involved in the fires.

On January 3, 2025, Ford received a fourth report of a fire involving a 2022 model year Ford F-150 BEV. On January 10, 2025, Ford Engineering received a battery array that had been replaced in one of the affected vehicles prior to the fire event.

From January 2025 to February 2025, Ford conducted teardown analysis on this battery array and continued this detailed review
of the supplier's manufacturing process.
On January 24, 2025, while this teardown analysis and review was ongoing, Ford’s Field Review Committee authorized Harvest Program 25H02 to obtain additional physical samples from the field for in-depth evaluation and root cause analysis to facilitate further testing and understanding of root cause.

On February 2, 2025, based on the teardown analysis on the returned array, Ford identified
evidence of misaligned electrodes in the high voltage battery cells. The supplier also identified evidence of cathode shift on eight stacker machines between two production lines based on a review of historical data for cells manufactured between January 3, 2022 and April 1, 2023. This manufacturing concern resulted in overlap that did not meet the supplier’s design requirement.
Some of the cells in the vehicles that experienced fires were built in this timeframe.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire that is under investigation.

On February 21, 2025, Ford’s Field Review Committee reviewed the concern and approved a field action.
Ford is not aware of any claims of crash related to this concern. Ford is aware of one claim of
injury and five reports of vehicle fire that may be related to this concern and are under further
investigation.

You may be right, that the Harvest Program 25h02 is related to this 25s18 Safety Recall (i will have 3 of my 9 modules replaced), but is there any documentation that directly says that?

 

[Grumpy2]

I have the following, as part of the NHTSA Report on Battery Fires dated 28 Feb 2025:

Ford Recall 25S18 Chronology includes:

"On January 3, 2025, Ford received a fourth report of a fire involving a 2022 model year Ford F 150 BEV. On January 10, 2025, Ford Engineering received a battery array that had been replaced in one of the affected vehicles prior to the fire event. From January 2025 to February 2025, Ford conducted teardown analysis on this battery array and continued this detailed review of the supplier's manufacturing process. On January 24, 2025, while this teardown analysis and review was ongoing, Ford’s Field Review Committee authorized Harvest Program 25H02 to obtain additional physical samples from the field for in-depth evaluation and root cause analysis to facilitate further testing and understanding of root cause. "


It is confusing why it took 6 months before Harvest letters were received by folks .....

Sponsored