Wrench light, charging errors at 65-66%...

[jefrank]

Guessing at just under 39 months and 42k miles I have developed a bad module in the battery pack. Got in the other morning and instantly got a wrench light. Charge was at 90% as expected, but could see power was reduced to 57%. Had stuff that had to be done so off I went. All good, just reduced power. Subsequent recharge failed at 66%, but again had places I had to be. Wrench light remains and charge failed at 65% last night. Hoping the local dealer has capacity to get it into the shop on Monday. Sigh.

Edit: Tagging Brian, not AI, on the thread.... @Ford Motor Company

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[The Weatherman]

Sorry to say, that is a pretty clear sign of a bad module readout. If you haven’t seen any OTAs lately I’ld say it’s about a 99.0% chance it is a battery issue. Sorry, but hey you still have like 60k miles and 5yrs of protection to cover it.

 

[TaxmanHog]

Looking forward to your report when it's fixed!

 

[jefrank]

Sorry to say, that is a pretty clear sign of a bad module readout. If you haven’t seen any OTAs lately I’ld say it’s about a 99.0% chance it is a battery issue. Sorry, but hey you still have like 60k miles and 5yrs of protection to cover it.

Last OTA was Sept 26, so, yeah ... likely a bad module. Had my new 12v sitting in the barn so I swapped it in, just in case (old one was at 59% soh now that it's cold), but no change, as I anticipated would be the case.

 

[jefrank]

Update

Most local dealer (5 minutes away) wants me to just drop it off and wait until they can look at it. Eff that. Don't really like them that much anyway.

Next closest dealer (25 minutes away) said to drop it off Tuesday night and they can look at it on Wednesday or Thursday. This service advisor did mention needing to reset the BMS after changing out the 12v, so I just looked up the ritual that must be invoked when you don't have Forscan and handled that. He said it couldn't be done, but I knew better. lol

Both are saying loaners are weeks-long waiting lists, if it comes to that. Hoping they can diagnose and it remains drivable, if limited.

 

[GoodSam]

power was reduced to 57%

Jeff, what was your Build Month on your 2022, just to be a little more detailed, although I think all of the 2022's are susceptible? Battery size, SR/ER? [see my tracking spreadsheet linked in my signature] Hate to see these fails showing up at higher mileages instead of showing up right away. The main thread of Power Malfunction/Reduced Power has many of these cell/module fails, with later Ford software updates reducing power to 57%. https://www.f150lightningforum.com/forum/threads/powertrain-malfunction-reduced-power.12439/ Hope you get a quick turnaround on the replacement. Yes, keep it going until they are ready to do the work if you can. Frustrating to have the truck just sitting at the dealer when it is still usable.

I still do not know what causes one of the 90 (SR) or 96(ER) cells, made up of 4(SR) or 5(ER) cell pouches in parallel, to show a lower voltage than the others. Chemistry gone bad? Stress at the layer interfaces? Poor manufacturing consistency of the layers (anode, electrolyte, cathode)? I had 3 of the 9 replaced in my SR due to Safety Recall 25S18 possible "electrode misalignment", I think, of the pouches that could cause a short, traced back to a bad assembly machine.

Contact the BEV customer service, and if no loaner from dealer, rent a Ford and the BEV might make you whole if the dealer will not cover the cost, I heard after renting a Hyundai that was over the daily limit.

 

[jefrank]

Jeff, what was your Build Month on your 2022, just to be a little more detailed, although I think all of the 2022's are susceptible? Battery size, SR/ER? [see my tracking spreadsheet linked in my signature] Hate to see these fails showing up at higher mileages instead of showing up right away. The main thread of Power Malfunction/Reduced Power has many of these cell/module fails, with later Ford software updates reducing power to 57%. https://www.f150lightningforum.com/forum/threads/powertrain-malfunction-reduced-power.12439/ Hope you get a quick turnaround on the replacement. Yes, keep it going until they are ready to do the work if you can. Frustrating to have the truck just sitting at the dealer when it is still usable.

I still do not know what causes one of the 90 (SR) or 96(ER) cells, made up of 4(SR) or 5(ER) cell pouches in parallel, to show a lower voltage than the others. Chemistry gone bad? Stress at the layer interfaces? Poor manufacturing consistency of the layers (anode, electrolyte, cathode)? I had 3 of the 9 replaced in my SR due to Safety Recall 25S18 possible "electrode misalignment", I think, of the pouches that could cause a short, traced back to a bad assembly machine.

Contact the BEV customer service, and if no loaner from dealer, rent a Ford and the BEV might make you whole if the dealer will not cover the cost, I heard after renting a Hyundai that was over the daily limit.

I don't know the build month of my Lariat ER off the top of my head (and the truck is now at the dealer so I can't check the label), but I'd guess June or July since I took delivery in late August after someone else refused delivery on their order.

I will definitely contact BEV customer service once I hear back from the dealer with a confirmation on the issue.

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