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

[GoodSam]

@ivegotmyowngas @Wattsgas @jonnybbomb @Old Aviator @CybertruckLightningMan @Hammick @JPro @Traconesu @Storm Breaker @Mpi @instantfob
I have been tracking HV Battery module replacements (see spreadsheet link in my signature) and for this Safety Recall 25S18 that we have been part of, I am looking for Build Month/Year (on top of door sticker),Year & Model, ER vs SR, and mileage (not so important) at time of service. Nerdy me, I am curious if the batch of misaligned electrodes were made late in 2022, like mine (Oct, 2022 build month/year), or spread out over all of 2022 and into 2023 (I see a couple of 2023s) or farther. I would appreciate any of that data that you can give me. I think I have some of your info (see the screenshot of my spreadsheet), but just looking to be correct. Looks like HV battery type is mixed between ER and SR types. Of course, Ford said there were 950 Lightnings involved in the recall, so our Forum members are just a small sample, unfortunately, to come to any amazing conclusions. I am also assuming that building the trucks are using HV packs that have been recently built as well. Thank You!

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[Mpi]

108 days later:

One module was replaced under the recall program. I also had a wiring harness replaced because it had a hole in it (? presumably they mean the casing), a bus replaced, and debris was cleaned out of the tub. The cause of this was prior work done by a different shop under the first owner.

I got the truck back Dec 23rd, but quickly realized it would only charge to 65%. Drove it sparingly for 10 days and got it back to the dealer Jan 3rd. Engineering diagnosed a bad module and also replaced the becm. Ford continued to cover the loaner costs, as they should. Jan 24th went back again to pick it up, but I could tell it was still not charging past 65%. More precisely, SOC would snap from 65% to 100%, so it looked fully charged to them.

Finally I got it back in service on Feb 4th. The issue, apparently, was actually a bad harness connector on their midtronics balancer, so it looked like the modules were balanced but were not.

Upon return the SOC variation was about 4% and the battery SOH reading 83.5%. It went in with 98.5% SOH. Slowly the SOC variation has fallen to about 2%, and SOH now reads 90%. I hope this will continue to improve with time as the new BECM learns, and not that the whole process stressed and weakened the battery.