Weird Charging Issue -- Possibly after module replacement

[AntJohn73]

I have a 2023 Lariat ER. I had module #9 replaced in late October. I am not sure if this issue is related to the module replacement. i wanted to see if anyone had an opinion. I occasionally charge to 90 or 100 percent. I normally only charge to 80%. I know that the truck turns down the current between 90 to 100. Due to the cold weather, I recently charged to 90%. I noticed that the truck turned down the current once it reached 80%. This never happened before. It is almost like the truck thinks it is at 90 instead of 80. When the truck stopped charging at 90, the display read 100. The guess o meter estimated milage was closer to what it would be at 90 instead of 100. As soon as I "started" the truck, the percentage went down to 90. Last night, I charged from 70 to 100. Again, the current ramped down as soon as it hit 80. The display and app read 100% but the available milage is only 254 which is more consistent with 90% instead of 100%. As soon as I "started" the truck this morning, the display changed to 87% but the guess o meter remained at 254. It seems to me that maybe the pack was not balanced properly? The temperature here in New Jersey is pretty cold (about 29 degrees) but I know I did not have an issue last year.

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[Heliian]

How much current are we talking here?

Which display changes and what does the other one say at that time?

 

[The Weatherman]

80% is the cliff that the rate follows off. It takes as long to charge from 80 to 100 as it does to charge from 20 to 80.

 

[TaxmanHog]

Just to confirm, you are achieving 100% SOC at the end of the charging session correct?

Hoping that your module #9 has fully balanced with the others over the past 3+ months since the service was completed.

Otherwise, it's not unusual to see the GOM predicted range to drop in the cold season, my SOC is 88% and the predicted range is 236 miles (ER 131 kWh pack), on warmer days it's a little higher in winter, and much higher in the summer.

The rate of charging definitely tapers off as the SOC increases, this is also normal.

EDIT:

I just remote started the truck, which refreshes Ford App, the SOC is now 89% and the GOM is 242, outside temperature has increased a little in the past 2 hours when I parked it in the driveway, exposed to sun.

 

[Maquis]

Did the dealer perform the cell balancing procedure after replacing the module? If not, you’re going see screwy numbers for a couple of months while they balance themselves.

 

[Newton]

You need to get an OBDII dongle and Car Scanner Pro to really drive yourself mad. There are two states of charge that the BMS has - ‘state of charge’ that you never see and ‘state of charge displayed’. The relationship between the two is not linear or even predictable. Neither is particularly accurate. To really get a sense of what is happening you have to monitor the battery voltage but I eventually decided that it wasn’t worth the effort - on a trip I pretty much just charge when I feel like it anyway especially now that we have Tesla access.

If you really want to charge to 100%, leave it on the charger well after it displays 100%.

 

[Mpi]

I am having a similar issue after Module replacement. I got mine back on Dec 23rd and have cycled the battery a few times. Every time it charges back to about 65% then soc jumps to 100% and it's done (no balancing happening).

My module soc variation was about 16% via car scanner, now up to almost 19%. Bad module or balanced incorrectly, either way I'm taking it back in on Monday.

 

[Grumpy2]

Bad module or balanced incorrectly, either way I'm taking it back in on Monday.

You have had quite a journey on this issue. Is this the same dealer that declared the battery had been worked on and reassembled incorrectly with pinched tubes and wiring back in October?

There is a specific procedure and tools to balance the battery after a module is replaced, but it takes time while the truck just sits on the lift taking up valuable space. Ford apparently gave the dealers some slack and pushed the balancing to the owner saying it may take 22 days of use & charging for the cells to be balanced.

Please keep us posted ...

 

[Mpi]

@AntJohn73 I also have a code "P0B24(21) Hybrid battery A - voltage instable". I'm curious if you have it as well.

@Grumpy2 Yes, the same recall repair. I was planning to write a follow up over there when its finally done.

 

[AntJohn73]

Thanks for all of the replies. Yes, it does reach 100% but it drops down right after the truck is "started". I believe they properly balanced the modules after #9 was installed. There are no codes at this point. Maybe is is the cold weather. I do not know. @TaxmanHog My bad! I forgot that the current drop off occurs at 80%!! I attached an image of what the charger is actually doing so you have a better idea. Again, maybe it is just the cold weather. I have a friend with FDRS. I would like to see the individual cell SOC just to be sure.

 

[B177y]

So, I've never heard about the current "dropping off" at 80% unless you are using a DCFC. Level 2 charging with my Emporia 48 amp at home is 48 amp up to 98 or 99%, then it slows down as the cell balancing takes place.

DCFC slows at 80%, and slows again at 90%. Just making sure I'm on the same page here as everyone else.

 

[AntJohn73]

Yes, just to be clear, it is level 2 charging.

 

[B177y]

Yes, just to be clear, it is level 2 charging.

Roger that. With the behavior you described in the OP, I would bring it back to the dealer and replicate the issue with them before leaving. Have the dealer check for codes and provide an explanation of everything they did to fix the problem. Post the redacted invoice here that shows all of the work that they did as there are some very talented people on the forum that can tell the difference between real work and BS. Be prepared to have alternate transportation for a while, while the dealer figures this out.

 

[AntJohn73]

I am sure it will eventually be worked out. I appreciate everything. Again, maybe it is just the friggin freezing cold weather. We shall see.....

 

[Sealevel]

I had a module (#2) replaced and have not experienced any charging issues like you describe. My dealer did the balance and charged my battery (L2) to 100% before delivering it back to me. My routine is to L2 charge (32 amp) to 85% and to 80% when I use DCFC. Good luck and hope it is resolved as your modules rebalance.

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