HV battery junction box?

[kdxkid]

Hi All,

I purchased a used 22 Lightning ER a few weeks ago, with 34.5K miles. All was good, took a trip with the family (first time with EV) about 500 miles. As soon as we arrived, I ran out for an errand literally a mile down the road. When I left the store, the truck would not turn on - only accessory power. The truck indicated “pull over safely” red warning, had the wrench, and also a battery symbol.

Emergency roadside assistance came to try to jump the LVDC (12V) battery, but that didn’t fix it. We assumed lvdc battery was toast, so I went and picked up a new one (had to wait till next morning with truck abandoned at the store). The new battery also didn’t fix the issue either. Also at this point, every possible warning on the truck started to flash. The break pedal vibrated fast (while truck was off / stationary), all the screens ended up turning black, and random loud clicks came from the speakers. I finally called for a truck to come and bring it to a dealership.

Dealership does an inspection and initially also says they change the 12VDC, and it then started working… until shortly after it didn’t. They also pulled up the alert / code history and it showed significant repeated warnings about power train failure / reduced power (nearly daily), on dates from 2 months ago to nearly present. I don’t have any of those alerts in my FordPass app.

Finally today (4 days later) the dealership now says it is the high voltage junction box, and that they need to probably wait weeks to get the part prior to doing the install. Also since I didn’t purchase it there, they are saying they won’t do a lender vehicle… and more I am 500 miles from home with my family (2 small kids).

I am really concerned with the reliability of this vehicle now - seeing how it has been throwing codes for months. Has anyone else experienced something like this? Does Ford not provide vehicles for warranty work when your vehicle fails? I’m really disappointed in the truck and service I’ve received so far from Ford.

thanks

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[electricpig]

Doesn't help your situation, but this the first report of the hvb junction failure in a Lightning. Mach-E, yes, but not int a Lightning. If the error codes go back that far, then that is suspicious that it would show up as a used vehicle.

There are reports weekly of this error or that failure in this forum and elsewhere, but the people having issues are far far more likely to be here to share their situation, just as you are. Not blaming them, just the way it is. That said, there are those trucks that seemed to have had drunk monleys working on the assemble line. Maybe you can get a repair history from Ford, and look into its history via Carfax or similar. However there is not absolute way to determine if you got the drunkonkey assemble.

Perhaps a extended warranty would be appropriate for your concerns.

Hope you get things resolved in as quickly and painlessly as possible.

 

[kdxkid]

I’m not share what you mean by: then it is suspicious it would show up as a used vehicle.

also - what do you mean by saying there are reports here of this error or failure but people are much more likely to show up here… not really clear what you mean sir.

thanks

 

[Firn]

Doesn't help your situation, but this the first report of the hvb junction failure in a Lightning. Mach-E, yes, but not int a Lightning. If the error codes go back that far, then that is suspicious that it would show up as a used vehicle.

There are reports weekly of this error or that failure in this forum and elsewhere, but the people having issues are far far more likely to be here to share their situation, just as you are. Not blaming them, just the way it is. That said, there are those trucks that seemed to have had drunk monleys working on the assemble line. Maybe you can get a repair history from Ford, and look into its history via Carfax or similar. However there is not absolute way to determine if you got the drunkonkey assemble.

Perhaps a extended warranty would be appropriate for your concerns.

Hope you get things resolved in as quickly and painlessly as possible.

Not quite unfortunately. I had mine fail and documented it here, and there are a few threads around as well.

FAR less of a concern than the Mach-E, but it has happened to a few with lightnings.

Back to the OP

Mine failed and the dealership had parts in a few days and fixed it in one day. Hopefully your experiance is the same.

Oh, and check your coolant level regularly after. If they didn't burp the system well enough it will go down.

 

[Henry Ford]

You might have luck getting a loaner with the Ford BEV team. They are available 24/7 except certain holidays. Since tomorrow is a certain holiday I suggest contacting them ASAP.

I think what @electricpig was trying to say is that people tend to set up accounts and post here when their trucks break. There's a distillation effect here that makes it seem like everyone has a broken truck. I don't know if a Lightning is more or less reliable than a gas F150. It's definitely not as reliable as a Toyota.

 

[kdxkid]

Not quite unfortunately. I had mine fail and documented it here, and there are a few threads around as well.

FAR less of a concern than the Mach-E, but it has happened to a few with lightnings.

Back to the OP

Mine failed and the dealership had parts in a few days and fixed it in one day. Hopefully your experiance is the same.

Oh, and check your coolant level regularly after. If they didn't burp the system well enough it will go down.

what symptoms did you experience prior to being told this was the failure?

also I’m out of town at random ford dealership in a rural area. They said it would be safe to drive while waiting on the part (prior to fixing)….. that made me concerned with their ability and knowledge to repair.

last - were you experiencing power train failure alerts? Apparently this had been happening nearly daily for months + prior to me purchasing the vehicle. I had to call ford and have the dealership pull alert history, as none of it is on my FordPass app.

 

[RickLightning]

Dealership should have connected the car to start with. Repair us under warranty, and BEV team should authorize a loaner and gas.

 

[Henry Ford]

They said it would be safe to drive while waiting on the part (prior to fixing)….. that made me concerned with their ability and knowledge to repair.

Your truck currently runs?

 

[hturnerfamily]

this sounds more like a simple GROUND issue, with the 12v battery, since 'accessory' mode continues to work, but when you put the larger 'load' when you turn the truck 'ON', it can't handle the amount of power needed... and since you've experienced some of these 'ghost' issues, from time to time, a ground is likely the source. The HV battery pack needs full compliance from that simple little 12v battery to make it's connections correctly, to allow the truck's HV systems to work, fully.

yes, a loose connection, unfortunately, can create havoc within an electrical system, sometimes looking just fine, then, suddenly, for no reason, NOT working correctly...

and, with an original PRO SR, no, I've never in 56,000+ miles, towing a camper more than 1/2 of that, experienced ANY issues, not even simple ones... no, there is no 'reliability' issues with these trucks...

but, yes, you are driving a very ELECTRICAL-based vehicle, where a simple connection can present what seems like catastrophic problems, although, honestly, they are NEVER that complicated. Ford techs are new to this vehicle, so, yes, they don't always have the hundred years of experience like they do with the gas versions of trucks... or even the F150 series, since 1948.

Sometimes we have to tell THEM what the problem might be...


I remember my first '66 Mustang convertible, and then my second, both were very 'basic' and simple engine bays... but, don't let that fool you: the solenoid could be a problem. the alternator could present a problem, etc., although, once the car was started, even if the alternator didn't charge the 12v battery, it didn't matter - if you kept the car running, it would continue to run.

fast forward to later years, though, with a Honda Prelude: NO! if that little 12v battery died, the CAR DID TOO! My Prelude's engine shut off, all I could possibly do was COAST.... those vehicles RELIED on the 12v battery just to keep the engine running.

 

[kdxkid]

Your truck currently runs?

they say it does… but my concern is it will stop somewhere even less convenient than it did last time. I am 500 miles from home, with my small children. I don’t want to breakdown on a random highway somewhere. At least here I was near my in laws.

 

[kdxkid]

this sounds more like a simple GROUND issue, with the 12v battery, since 'accessory' mode continues to work, but when you put the larger 'load' when you turn the truck 'ON', it can't handle the amount of power needed... and since you've experienced some of these 'ghost' issues, from time to time, a ground is likely the source. The HV battery pack needs full compliance from that simple little 12v battery to make it's connections correctly, to allow the truck's HV systems to work, fully.

yes, a loose connection, unfortunately, can create havoc within an electrical system, sometimes looking just fine, then, suddenly, for no reason, NOT working correctly...

the accessory power was initially working, but then it stopped and every weird warning started on the vehicle. Screen went black couldn’t lock or unlock doors, and the speakers were making loud popping or clicking noises.

to me - I’m really not reassured that they know what the fix is

 

[Henry Ford]

they say it does… but my concern is it will stop somewhere even less convenient than it did last time. I am 500 miles from home, with my small children. I don’t want to breakdown on a random highway somewhere. At least here I was near my in laws.

The truck isn't going to die on a highway. If it fails it will refuse to start and you can have it towed. There's a very high chance you'll make it home.

Presumably, you are planning on being at your current location for a few more days. Drive it, gain confidence. If it dies again you are in the same situation you're in now.

Just playing out the options. If it were me I'd want to get it home so I didn't have to wait for to be fixed or drive 1000 miles to pick it up.

 

[electricpig]

I’m not share what you mean by: then it is suspicious it would show up as a used vehicle.

also - what do you mean by saying there are reports here of this error or failure but people are much more likely to show up here… not really clear what you mean sir.

thanks

Sorry for clarity. I was wondering if previous owner had saw those codes and traded/sold the truck because of it.

Second, in forums like this, the ones with problems are far more likely to post. They go looking for answers (like yourself) and post the problems. People that don't have problems are probably not going to bother.

 

[electricpig]

Not quite unfortunately. I had mine fail and documented it here, and there are a few threads around as well.

FAR less of a concern than the Mach-E, but it has happened to a few with lightnings.

Back to the OP

Mine failed and the dealership had parts in a few days and fixed it in one day. Hopefully your experiance is the same.

Oh, and check your coolant level regularly after. If they didn't burp the system well enough it will go down.

Yeah, meant to say that I hadn't seen reports, but the brain goes faster than the hands. Thanks for the correction.

 

[Ricks Lightning]

How long ago did you purchase the used 2022 lightning. Did the selling dealer give you any kind of extended warranty? Did you pull up a carfax report on it to see it's track record?

Who knows why they sold the truck? But there should be some form of history with it.
Rick

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