SUCCESS: Battery Pack MODULE Replacement: '22 Pro SR @ 62,000 miles

[Zapitgood]

I had the 8 and 9 modules recently replaced also had to replace the BECM on my 2022 Lariat ER. The truck went down on October 28 and was ready for pickup on November 7. I had 60819 miles when it had to be towed. The dealer who completed the repair was awesome (shot out to Boulevard Ford in Millsboro DE) their EV tech knew what he was doing. I picked up the truck 10/15 and drove over 400 miles home no problems. Yea the coolant is something to monitor after battery work. I forgot to stop by the parts department and pick up some coolant for the trip and towards the end of the trip the temp gauge was reading slightly past half way mark where it t normally sits. When I got home and checked the coolant reservoir it was empty. Truck is running like it should!

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[GoodSam]

truck went down on October 28 and was ready for pickup on November 7. I had 60819 miles when it had to be towed. The dealer who completed the repair was awesome (shot out to Boulevard Ford in Millsboro DE) their EV tech knew what he was doing. I picked up the truck 10/15 and drove over 400 miles home no problems.

Sorry to be picky: Truck modules replaced by 11-7-25...so truck picked up on 11-15-25 and driven, with extra coolant needed? Fairly fast turnaround time, but EV Tech needed to evacuate coolant system to avoid empty reservoir, so there is room for improvement? Your case is on about line 857 of my tracking spreadsheet in my signature.

 

[GoodSam]

Does your data indicate an connection between the module failure and the density of cells, i.e., 55 cells vs 40 cells?
Or SR vs ER?
The 9 SR battery modules all have 40 cells, the ER has 8 modules with 55 cells and one with 40 (module 9 I believe).
I have seen at least one report of a module #9 failure.

I think module size type is not showing any advantage, glancing over the spreadsheet. I think cell/pouch density is the same, just larger aluminum module containers for the ER. Just huge percentage of early trucks having modules with bad cells. Horrible quality control or maybe engineering or both. I hope having 3 of my 9 modules replaced will cover me, but would not be surprised to see another one go bad.

 

[chl]

I think module size type is not showing any advantage, glancing over the spreadsheet. I think cell/pouch density is the same, just larger aluminum module containers for the ER. Just huge percentage of early trucks having modules with bad cells. Horrible quality control or maybe engineering or both. I hope having 3 of my 9 modules replaced will cover me, but would not be surprised to see another one go bad.

Thanks for the feedback.

Yeah, quality control problems with the batteries is a worry.

Seems random, but just wondered if the 40 cells ones were failing more than the 55 cells ones maybe because they were made on a different assembly line - guess that's not a factor though if not showing up that way in the numbers.

If it were the 40 cell modules, one would expect to see more SR trucks having problems than ER's on average I'd reckon.

According to the Ford table, the ER has eight 55 cell modules and one 40 cell module (#9 module) - total 480 cells.

In the SR all nine modules are 40 cell - total 360 cells.

The flash has three 40 cell modules (1, 2 and 9) and six 55 cell modules- total 450 cells.

Anyway, hope I got lucky with my 2023 Pro modules. Time will tell.

I have never had a single issue with my 2012 Leaf battery (24kWh), except the 100 mile range is impractical for any thing but local driving in my opinion.

Some early Leaf owners are upgrading their battery packs with plug-n-play packs from Japan and China, giving a range of closer to 500 miles on a full charge, for about $6,000. A limited warranty however, so I am leery of that given all the things that can go wrong.

 

[GoodSam]

If it were the 40 cell modules, one would expect to see more SR trucks having problems than ER's on average I'd reckon.

I am also not sure of what percentage of the Lightnings were SRs vs. ERs which would be important for making a judgement. I think more ERs have been made as getting a Pro was limited in the first year. Definitely both types have had bad cells, causing a module (or 2 or 3) to be replaced. Yes, so weird that 4 pouch cells would have the same problem as 5 pouch cells with electrode misalignment using the same machines? Maybe that is a cover for just having poorly made pouches that could end up in any SR or ER "cell" that could explode into a fireball!
Oh boy, I love a good conspiracy!

 

[RickLightning]

the dealer 'service writer' person can't tell me anything, as she's never had anything to do with 'battery replacement', or probably much with ANY electric vehicle... and she doesn't have the experience to even know where the techs are along on the process...

Service Writer to Tech: "Hey Bob, can you give me an update on the battery replacement so I can update the owner?"

That is why some people shouldn't work in Customer Service...

 

[hturnerfamily]

I am trying, really trying, to be 'patient' during this long process... but.... yes, agreed.

still nothing...

 

[pja3668]

I’m a couple days shy of 7 weeks for my truck. Towed to the dealership on October 2nd. Today is November 17th. I wish I could give more information. My service writer is clueless. My customer advocate told me they told her 4 out of 5 arrays were changed so far. That was a couple weeks ago. This morning I was told the “batteries” plural had arrived and they were opening the “boxes”. So more modules? I don’t bother asking my service writer questions anymore because it’s like asking a 5 year old. Never clear communication or concise communication. It’s “I don’t know”, “I’m not sure”. That’s when I actually talk to him. Most times I leave voicemails for updates and don’t get return calls. It’s been a great experience (full and total sarcasm). *I did sneak up to the window this afternoon to look in and they are actually working on my truck and had what appeared to be a new module on a cart next to my “dropped battery”. Not sure if I care anymore if they can fix it or not. I’ve begun to think of what I’m going to replace the Lightning with. Sucks. I loved the truck for 2.5 years.

 

[jefrank]

I had the 8 and 9 modules recently replaced also had to replace the BECM on my 2022 Lariat ER. The truck went down on October 28 and was ready for pickup on November 7. I had 60819 miles when it had to be towed. The dealer who completed the repair was awesome (shot out to Boulevard Ford in Millsboro DE) their EV tech knew what he was doing. I picked up the truck 10/15 and drove over 400 miles home no problems. Yea the coolant is something to monitor after battery work. I forgot to stop by the parts department and pick up some coolant for the trip and towards the end of the trip the temp gauge was reading slightly past half way mark where it t normally sits. When I got home and checked the coolant reservoir it was empty. Truck is running like it should!

I realize that in the grand scheme of things the cost of coolant is a drop in the bucket, but it seems wrong that owners are having to buy their own because the system wasn't purged of air sufficiently by the tech at the dealership.

 

[Zapitgood]

The coolant system/reservoir may have been filled seems like air has many area to be trapped in this system and seems like a common thing so no biggie to me. Yes a proper vacuume on the system should be expected.

 

[pja3668]

Almost 7 weeks but I just got the call it’s ready for pick up. Can’t wait to try to squeeze (the right, detailed) information out of my service writer. What exactly has been changed.

 

[GoodSam]

squeeze (the right, detailed) information out of my service writer. What exactly has been changed.

post pic of service write up if you can...amazing if 5 of the 9 HV battery modules replaced.

 

[hturnerfamily]

UPDATE: today my FORD app was revived

-the pack has been reinstalled, with a ~70% SOC
-the truck has been driven around the dealership, I can see
-it is now charging successfully...

 

[hturnerfamily]

I still haven't received any call from the dealership, though...

1 1/2 weeks since it went up on the lift...

more than a week before that just waiting for the diagnosis and battery module...

 

[hturnerfamily]

I got the call right at 5pm... "it's ready, can you come to get it before 5:30?"...

dang right I can....

cell 63 in module 7
... and, they also recharged/replaced coolant lines...

(on Friday, the service writer had told me that the 'tech' and the manager had to attend schooling at another larger dealer to get the 'know how' to complete this task.... "school of hard knocks")

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