My 2023 Lightning Lariat is getting a battery pack replacement!

[kstype]

Let’s loop in @Ford Motor Company here - they may ask for your VIN and may contact the dealer.

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[Fireetr73]

So - FMC is offering you a new discounted Lightning or are you on your own to work with a dealership?

Sorry, I miss spoke. I was clear that I didn’t want a discount on a new vehicle.

 

[Fireetr73]

UPDATE! I finally closed on the buy back yesterday. I’m happy with the outcome, but not happy with the process. Ford made it really hard. I have been without a vehicle for six months while still paying a big monthly payment. They weren’t easy to work with. For that reason and others I will be moving on from FORD and the EV experience for now. Back to GMC. Denali this time. I wish all of you well and hope that none of you have to go through this process. God Speed!

 

[mags]

My truck is dead at the dealer right now. It needs a heater module that is on backorder and there's no ETA. No loaner, either.
I really, really hope I don't have a similar experience, it's been 10 days...

 

[GoodSam]

Build dates of your trucks (top of driver's door sticker)? Helps us to see the relationship to problems with factory production dates that can give others a heads up on what to lookout for. Thanks!
@Fireetr73 @Vito @Freddyfresh @Airboss @CyberIllusion @davehu @ooSHAZAMoo @CVDUDE @T i h o r @B. Lane @Arni @haresource2 @atguru @calarch @dbelcher5761 @patrickj62 @boseephuss @SunshinestateF150 @DavePastry

 

[Fireetr73]

Build dates of your trucks (top of driver's door sticker)? Helps us to see the relationship to problems with factory production dates that can give others a heads up on what to lookout for. Thanks!
@Fireetr73 @Vito @Freddyfresh @Airboss @CyberIllusion @davehu @ooSHAZAMoo @CVDUDE @T i h o r @B. Lane @Arni @haresource2 @atguru @calarch @dbelcher5761 @patrickj62 @boseephuss @SunshinestateF150 @DavePastry

8/1/2022

 

[Fireetr73]

My truck is dead at the dealer right now. It needs a heater module that is on backorder and there's no ETA. No loaner, either.
I really, really hope I don't have a similar experience, it's been 10 days...

As soon as it hits the day limit in your state, lemon law it! That’s my recommendation. It gives you two options, 1) FORD will bump you to the front of the line to repair it, 2) You can get out of the vehicle all together.

 

[boseephuss]

Build dates of your trucks (top of driver's door sticker)? Helps us to see the relationship to problems with factory production dates that can give others a heads up on what to lookout for. Thanks!
@Fireetr73 @Vito @Freddyfresh @Airboss @CyberIllusion @davehu @ooSHAZAMoo @CVDUDE @T i h o r @B. Lane @Arni @haresource2 @atguru @calarch @dbelcher5761 @patrickj62 @boseephuss @SunshinestateF150 @DavePastry

I'll get that information added and reply once home this evening.

 

[pja3668]

This thread hasn't been active in over a year. But I have something to add if anyone is still following. My truck bricked itself on October 2nd. Towed to dealership, after four hours. They initially thought it was the gear shift module. which was replaced (hopefully with a better unit then the original). Then they said it was the battery array assembly. Which someone on here (Taxman?) said was a module. My dealership has had zero communication. Every time I call I leave a message and don't get a call back. Any information I've got was through the Ford customer advocate (as nice and helpful as she has been I can tell she wouldn't have a clue about certain things). She told me yesterday that "4 out of 5 modules are replaced so far". With the fifth on order. I only have 35K miles on my 2023 SR XLT. Is there somewhere we can see data on how many batteries have had work/modules replaced. And how many modules. I would think a forum would be the only place to compile that, as Ford wouldn't willingly share that.

 

[RLXXI]

This thread hasn't been active in over a year. But I have something to add if anyone is still following. My truck bricked itself on October 2nd. Towed to dealership, after four hours. They initially thought it was the gear shift module. which was replaced (hopefully with a better unit then the original). Then they said it was the battery array assembly. Which someone on here (Taxman?) said was a module. My dealership has had zero communication. Every time I call I leave a message and don't get a call back. Any information I've got was through the Ford customer advocate (as nice and helpful as she has been I can tell she wouldn't have a clue about certain things). She told me yesterday that "4 out of 5 modules are replaced so far". With the fifth on order. I only have 35K miles on my 2023 SR XLT. Is there somewhere we can see data on how many batteries have had work/modules replaced. And how many modules. I would think a forum would be the only place to compile that, as Ford wouldn't willingly share that.

Any dealer can run an OASIS on the vin and pull up all warranty work. You can do it your self over on motorcraftservice.com under the Service Info tab $26 access fee for 3 days last I looked. Use the drop down pricing menu.

 

[Firn]

. Is there somewhere we can see data on how many batteries have had work/modules replaced. And how many modules. I would think a forum would be the only place to compile that, as Ford wouldn't willingly share that.

See a couple posts down by @GoodSam

https://www.f150lightningforum.com/forum/threads/bad-battery-module.24376/

 

[Grumpy2]

On Oct 27th you posted "My 2023 XLT SR with 35k miles has been at my local dealership for a month. " Confirmed to be in the shop October 2nd.

Now 5 weeks later you have been told:

"4 out of 5 modules are replaced so far".

Have you contacted an attorney? Investigated the Lemon Law in NJ? You have full justification to get Ford to take this problem away from you.

By the way, It would be HIGHLY unusual (impossible??) to replace more than 2 or 3 battery modules in one truck based on folks here on the forum. They must be talking about individual computer modules .... Something smells very bad ...

 

[GoodSam]

Is there somewhere we can see data on how many batteries have had work/modules replaced. And how many modules. I would think a forum would be the only place to compile that, as Ford wouldn't willingly share that.

Go to the spreadsheet in my signature (I currently have you on line 450). What is the build date (mo/yr) of your truck? (see the top of the driver's door post sticker).
Ford initially said 4% of first couple of years Lightnings would need "one or more" of the 9 battery modules(arrays) of the whole HV battery pack replaced (see p9 note in CSP 23B57 dealer 10pg letter 9-23-2023). Then there was a Safety Recall 25S18 that may have added another 950 trucks (my Oct, 2022 XLT SR had 3 of the 9 replaced). Terrible manufacturing, Ford is obviously not achieving ISO 9000 standards? @Ford Motor Company

Perplexity gave me this:
"

• Automotive manufacturers often target "Six Sigma" quality levels (less than 3.4 defects per million opportunities), which correspond to significantly less than a 0.01% defect rate, particularly for critical safety and reliability-related parts.
• Realistic defect rates for critical automotive components that meet long warranty periods and customer reliability expectations typically range between 10-50 parts per million (0.001% to 0.005%) depending on the complexity and criticality.
• Continuous improvement, robust supplier quality management, extensive testing, and advanced quality controls support achieving these very low defect levels.
• For electric vehicles like the F150 Lightning, battery and motor reliability expectations are especially high, often requiring targeted failure rates far below 0.01% individually.

In summary, to meet the goal of fewer than 1 in 10,000 trucks needing major warranty repairs on critical systems, the defect percentage for each critical part generally needs to be in the low parts-per-million (PPM) range, often around 0.001% to 0.005%, with a strong focus on high reliability and redundancy across systems. This aligns with automotive industry best practices for long-term warranties and reliability commitments."

 

[mr.Magoo]

By the way, It would be HIGHLY unusual (impossible??) to replace more than 2 or 3 battery modules in one truck based on folks here on the forum. They must be talking about individual computer modules .... Something smells very bad ...

Then again, if the dealership don't know what they're doing, the good ol' "replace sh-t until it works" method would render results like this.

 

[TaxmanHog]

This thread hasn't been active in over a year. But I have something to add if anyone is still following. My truck bricked itself on October 2nd. Towed to dealership, after four hours. They initially thought it was the gear shift module. which was replaced (hopefully with a better unit then the original). Then they said it was the battery array assembly. Which someone on here (Taxman?) said was a module. My dealership has had zero communication. Every time I call I leave a message and don't get a call back. Any information I've got was through the Ford customer advocate (as nice and helpful as she has been I can tell she wouldn't have a clue about certain things). She told me yesterday that "4 out of 5 modules are replaced so far". With the fifth on order. I only have 35K miles on my 2023 SR XLT. Is there somewhere we can see data on how many batteries have had work/modules replaced. And how many modules. I would think a forum would be the only place to compile that, as Ford wouldn't willingly share that.

You have 9 modules in total, so they've apparently targeted 5 defective modules of the 9.

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