Not charging correctly after battery module and charge port replacement

[DarkStar]

I’ve had a battery module and a charge port replaced already. Received my truck last week and it is not DC charging correctly. The dealer charged it for 5 minutes on a DC charger and declared it good enough since it did not have the amber ring indicator at the charge port.
Has anyone had this happen as well?

@Ford Motor Company ,hoping you’d see this and please help me on a course of action for next steps to get my truck functioning properly!

2023 Lightning XLT SR

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[The Weatherman]

I’ve had a battery module and a charge port replaced already. Received my truck last week and it is not DC charging correctly. The dealer charged it for 5 minutes on a DC charger and declared it good enough since it did not have the amber ring indicator at the charge port.
Has anyone had this happen as well?

@Ford Motor Company , hoping you’d see this and please help me on a course of action for next steps to get my truck functioning properly!

2023 Lightning XLT SR

@Ford Motor Company

 

[Zprime29]

You need to provide a little more information. What was the SOC that the dealership charged to? Are you trying to charge on AC or DC? Did the dealer test AC?

 

[Heliian]

it is not DC charging correctly.

What do you mean?

 

[DarkStar]

After the charge port was replaced, the dealership AC charged from 24 to 100% (14 hours). They said it was fixed and ready to be picked up but I said they needed to test it on a DC charger so they drove it down to 92% and it wouldn’t charge.
Ford EV helpline informed them they needed to drive it down below 50% and then DC charge. They drove it down to 45% and charged to 52% in 6 minutes but they didn’t pay attention to the charge rate.
I grabbed my truck the next day and took it to a different DC charger. It stair stepped up to 90 KWh then held steady to 80%. From 80 to 90% it stepped down to 40% but held steady, not tapering down like the normal curve.
Subsequent charges between 50-80% have been similar as it steps up to 90 KWh and holds steady. Nothing higher than 90 KWh.
Typical charge before module and charge port replacement was a surge up to 170 KWh for a few minutes, then down to around 135-140 KWh until 80%. After 80%, the charge cliff and the downward decline.
Curious why 90 KWh seams to be the upper limit now.
Thanks everyone. I appreciate your time and expertise!

 

[PreservedSwine]

That doesn't sound abnormal to me

Get into the 30% range and see if you get the larger curve. I won't pull over 150 if I'm over~50% iirc

 

[DarkStar]

I charged from 28% to 80% with the same result at a different station (400KW HyperFuel station). Up to 90 KWh and held steady all the way to 80%. No spike to 170 or curve.

 

[Grumpy2]

I charged from 28% to 80% with the same result

That is not my experience from 28% to 80%. I am at a loss to understand why the truck is controlling the charge rate to a limit of 90 with SOC that low. I believe it is primarily temperature extremes and SOC that normally makes my truck slow the charging rate.

My only idea: How long ago was the battery module replaced and have you monitored the coolant level since the module replacement? Seems there should be a Diagnostic Trouble Code ...

 

[Heliian]

Everything is fine, just keep using it normally.

 

[TaxmanHog]

Continue driving for ~20 more days, possibly the replacement module isn't in perfect sync/match with the rest of the pack, it should normalize over about 3 weeks, by then you should be seeing those peak charging rates again.

Definitely pay attention to the coolant degassing bottle on the drivers side of the frunk, the level might drop some as air is purged from the battery pack.

 

[Mike G]

Has it been 22 days yet?

 

[Zprime29]

I agree with others, give it another 2 weeks and see if things improve after that. 90kW is not awesome (and it sounds like you need to DCFC fairly regularly) but it's decent. It's a shame the dealer didn't think to DC charge first, then top up with an AC test. It's like these guys have no idea how EV's work. Keep us posted if the DCFC rate improves.

 

[Adventureboy]

Besides giving the new module a few weeks to sync up with the rest of the battery pack, charge it to 100% a few times and leave it sit there until the SOC says 100% before unplugging. This helps top balance all the cells in the pack. It can take several hours to go from 99-100% as it does this balance so you need to give it the time to complete.

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