Upgrading F-150 Lightning Battery Pack [VIDEO]

[ctuan13]

That’s probably true about the warranty but in this case the truck was at 143k miles and well out of warranty anyways. It’s amazing this pack is so plug and play. Huge bonus points to Ford engineers on this one. And what a cool step by step video.

This highly serviceable design and now ease of swapping major components is what gives me a lot of hope for a robust cottage industry of aftermarket battery packs and modding as these truck age and become more and more accessible to modders and project builders.

In a lot of ways, the Lightning feels like a modern day Crown Vic of EVs with how easy it is to work on in comparison to basically every other competitor in the segment.

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[Timeless Epoch]

This highly serviceable design and now ease of swapping major components is what gives me a lot of hope for a robust cottage industry of aftermarket battery packs and modding as these truck age and become more and more accessible to modders and project builders.

In a lot of ways, the Lightning feels like a modern day Crown Vic of EVs with how easy it is to work on in comparison to basically every other competitor in the segment.

The lightning might be the best F150 Ford made since the 300 I6.

 

[ajbessinger]

With the bad module removed, would it still be possible to operate? Possibly as a home storage unit? How hard would it be to have the charge port operational, so it could work with a V2X bidirectional charger? Same question for both ford or Tesla packs.

The onboard charger is a separate component from the battery. You wouldn't be able to run this as a "functional" pack with a module removed, so it's really a "parts only" unit where the good modules can be paired up with an aftermarket BMS and used for whatever 2nd life application you desire (powerwall, electric conversion, etc.).

The Tesla Model S "85kWh" packs could be modified and have 2 modules removed, and BMS master replaced to run them as a "70kWh" pack configuration. But again, you'd need a separate charger, and a way to communicate with the pack to make it functional. Again, these are best used for parting out where the modules are used standalone for 2nd life applications.

 

[tearitupsports]

The onboard charger is a separate component from the battery. You wouldn't be able to run this as a "functional" pack with a module removed, so it's really a "parts only" unit where the good modules can be paired up with an aftermarket BMS and used for whatever 2nd life application you desire (powerwall, electric conversion, etc.).

The Tesla Model S "85kWh" packs could be modified and have 2 modules removed, and BMS master replaced to run them as a "70kWh" pack configuration. But again, you'd need a separate charger, and a way to communicate with the pack to make it functional. Again, these are best used for parting out where the modules are used standalone for 2nd life applications.

Thats too bad, or I would have considered buying the one you have. It wouldn't need the onboard AC charger, but would still need enough of the system to plug in a CCS cable and do the CCS DC charging handshake for my V2X system to work with it.
It could also need some sort of coolant pump, although the home system would max out at 11 kW and wouldn't stress it much.

 

[OMO7]

so, let's see if this is the 'minimum' wrenching required to swap:

- disconnect 12v battery
- lift truck
- support battery pack*

- remove ground from rear of battery pack
- remove 3 bolts above battery pack HV connections
- remove 2 battery pack coolant lines
- remove 4 HV/Motors battery pack connections
(*or, support the battery pack, now)
- remove 8 battery pack support bolts

- lower and remove battery pack


do all over, in reverse, with new battery pack**

**of course, as Alex had to do, you may have to transfer HV Connection(s), if needed.

May want to disconnect the HV battery, but that's ultimately up to you.

 

[htobin]

Fantastic video. That guy is a genius.

 

[ZSC100]

So, is there a way to use the battery packs for home backup power? I know people have done it with old Leaf batteries and stuff, but how realistic is it for the SR batteries?

Absolutely, I have this exact project going on right now with the University of Tulsa. At the conclusion of the 25/26 school year we will publish the project open source, most likely on Github and one of the goals of the project is to make an interface/controller for the F150 Lightning battery to use it for alternative uses.

Basically the deliverables for this project are to use off the shelf, affordable, minimal hardware to interface to the Lightning's battery and control it for alternative uses. Basically the system provides a means of monitoring the battery and controlling its contactors so you can use it like any other battery. It will also be paired with the OEM 11.6kW charger for charging and balancing.

 

[Yzlvr]

Interesting. Any way to follow your progress? Forum, github?

Absolutely, I have this exact project going on right now with the University of Tulsa. At the conclusion of the 25/26 school year we will publish the project open source, most likely on Github and one of the goals of the project is to make an interface/controller for the F150 Lightning battery to use it for alternative uses.

Basically the deliverables for this project are to use off the shelf, affordable, minimal hardware to interface to the Lightning's battery and control it for alternative uses. Basically the system provides a means of monitoring the battery and controlling its contactors so you can use it like any other battery. It will also be paired with the OEM 11.6kW charger for charging and balancing.

 

[ZSC100]

Interesting. Any way to follow your progress? Forum, github?

Not until the class is over and the University approves posting, but I will post the final report and links to the Github it on the forums as soon as possible.

 

[biers]

Not until the class is over and the University approves posting, but I will post the final report and links to the Github it on the forums as soon as possible.

Will keep an eye on that. Guess I’ll hold on to my old SR pack. I was offered a whole $300 by Green Tech Auto. The guy on the phone apologized for the low offer but “that’s what the computer says”. Pretty good margin considering they charge $20k for a SR battery swap.

 

[jcar01]

He charged me $750 all in. Would have been less but the pack I bought had damaged connectors so swapping that harness out took extra labor. He had a second set of hand helping on mine and I had the truck back in less than three hours. Was also very nice to have it shipped to his shop where he could unload it from the friend truck with his forklift and he loaded my old pack onto the trailer for me.

Were is his shop located?

 

[PJnc284]

Were is his shop located?

Currently Portland, Oregon but he's mentioned that he'll be moving to NC and have a shop at the Out Of Spec track NCCAR) in Garysburg.

 

[biers]

Were is his shop located?

https://maps.app.goo.gl/bZRz5PhTbh8wPCU37?g_st=ic

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