Safety Recall 23S15 High Voltage Battery Replacement – 2023 Ford F-150 Lightning

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March 15, 2023 NHTSA CAMPAIGN NUMBER: 23V168000

High-Voltage Battery Pack May Short-Circuit

A battery short-circuit increases the risk of a fire.

 

NHTSA Campaign Number: 23V168

Manufacturer Ford Motor Company

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 18

 

Summary

Ford Motor Company (Ford) is recalling certain 2023 F-150 Lightning pickup trucks. The high-voltage battery pack may experience an electrical short-circuit when the battery is fully charged or near fully charged.

 

Remedy

Dealers will replace the high-voltage battery pack, free of charge. Owner notification letters were mailed March 31, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23S15.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


March 10, 2023

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD –
Safety Recall 23S15

Certain 2023 Model Year F-150 Battery Electric Vehicles (BEVs)
High Voltage Battery Replacement

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
F-150 BEV 2023 Rouge Electrical Vehicle Center January 20, 2023 through January 26, 2023

Affected vehicles are identified in OASIS and FSA VIN Lists. This program involves 18 delivered U.S. vehicles.

 

REASON FOR THIS SAFETY RECALL

Ford is recalling certain F-150 Battery Electric Vehicles due to a battery cell manufacturing defect which occurred over a four-week period starting at the end of last year. For vehicles built with these cells, the vehicle could experience a short in the High Voltage Battery at a high state of charge that could result in a vehicle fire.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to replace the High Voltage Battery. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of March 27, 2023. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $26,315 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealers for an appointment to have their vehicles remedied as soon as practicable.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES
The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting, or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title-branded and salvaged vehicles are eligible for this recall.

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed before the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with replacing the high voltage battery.

 

RENTAL VEHICLES

Dealers are pre-approved for up to 1 day for a rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the day(s) the vehicle is at the dealership for part replacement. Prior approval for more than 1 rental day is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.

 

PICK-UP AND DELIVERY

All customers affected by this program have the option of complimentary Vehicle Pick-up & Delivery service (at participating dealers). Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details.

 

ALTERNATIVE TRANSPORTATION

If a customer is unable or does not wish to rent a vehicle but still requires transportation, the rental reimbursement allowance can be used for alternative transportation. Alternative transportation is approved for $100 per day for both Ford and Lincoln customers. The dollar-per-day allowance can be cumulative across multiple rides per day (e.g. ride to work $20 and ride home $24).

  • Alternative transportation reimbursement can be claimed for both short-term and long-term scenarios.
  • Any amount over the cost-per-day limits will be the customer’s responsibility.
  • The customer will need to pay upfront and provide proof of payment to the dealer.
  • Dealers will then need to submit for reimbursement following the Rental Vehicle Reimbursement Process and then refund the customer.

Examples of alternative transportation:

  • Taxi
  • Public Transportation – Subway, Train, or Bus
  • Rideshare alternatives (Uber, Lyft, etc.)

 

PARTS REQUIREMENTS

Part Number  Description
-10B759- High Voltage Battery

 

Part Number  Description Order Quantity
VC-13DL-G Safety Recall 23S15 High Voltage Battery Replacement - 2023 Ford F-150 Lightning | small light Motorcraft® Yellow Prediluted Antifreeze/Coolant

(Up to 15.9 Liters per vehicle)

As Required

 


CERTAIN 2023 MODEL YEAR F-150 BATTERY ELECTRIC VEHICLES — HIGH VOLTAGE BATTERY REPLACEMENT

 

SERVICE PROCEDURE

NOTE: Technicians must be certified in specialty 44.

WARNING: Service of the high voltage system on this vehicle is restricted to qualified personnel. The required qualifications vary by region. Always observe local laws and legislative directives regarding electric vehicle service. Failure to follow this instruction may result in serious personal injury or death.

WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

1. Replace the high voltage battery. Please follow the Workshop Manual (WSM) procedures in Section 414-03-A.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 


Affected Vehicle VIN List

1FTVW1EL0PWG09271 1FTVW1EL5PWG11047
1FTVW1EL0PWG10095 1FTVW1EL6PWG09338
1FTVW1EL0PWG11005 1FTVW1EL7PWG08599
1FTVW1EL1PWG08985 1FTVW1EL7PWG09266
1FTVW1EL2PWG09451 1FTVW1EL8PWG08143
1FTVW1EL2PWG11054 1FTVW1EL8PWG08904
1FTVW1EL3PWG09569 1FTVW1EL8PWG09244
1FTVW1EL3PWG09605 1FTVW1ELXPWG07639
1FTVW1EL5PWG09167 1FTVW1ELXPWG09925

 

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March 15, 2023

23S15 – CERTAIN 2023 FORD F-150 BEV VEHICLES – VEHICLE FIRE

Chronology of Defect / Noncompliance Determination

Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.

February – March 2023
On February 09, 2023, Ford’s Critical Concern Review Group (CCRG) opened an investigation into a vehicle fire on a company holding lot. On February 04, 2023, the fire occurred in a 2023 model year F-150 BEV during a pre-delivery quality check while the vehicle was charging. On February 05, 2023, production of 2023 model year F-150 BEV was halted at Ford’s assembly plant.

From February 06 through February 09, 2023, the Ford engineering team de-energized the high voltage battery pack to allow access to the vehicle. Using computed tomography (CT) scans of the high voltage (HV) battery arrays, Ford and the supplier independently concluded the initiation point of the fire occurred within one of the HV battery arrays.

On February 10, 2023, review of production records at the supplier and at Ford’s assembly plant identified that suspect high voltage battery cells were produced at the supplier from December 14, 2022, to January 17, 2023.

Continued investigation by Ford and the supplier found that the vehicle fire started when cathode aluminum tabs contacted the anode electrode material, causing an internal short circuit when the cells were at a high state of charge. Ford and the supplier identified the processes on the supplier cell manufacturing line that led to these contact conditions. The Ford engineering team was able to replicate the contact condition through a Design of Experiments (DoE) performed at the supplier. While the CT scans and teardown parts from the suspect window confirmed the condition, parts from outside the window and from the other cell manufacturing lines did not show evidence of the contact conditions.

On March 02, 2023, further review of production records at the assembly plant found that 18 vehicles with cells built within the suspect time window were delivered to dealerships.

As of March 09, 2023, Ford is not aware of any warranty or field reports related to this condition.

On March 10, 2023, Ford’s Field Review Committee reviewed the concern and approved a field action.

Ford is not aware of any reports of accident or injury related to this condition.

###

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
FORD F-150 LIGHTNING 2023

 


9 Associated Documents

Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S15 Certain 2023 Model Year F-150 Battery Electric Vehicles (BEVs) High Voltage Battery Replacement

RCMN-23V168-3872.pdf 335.298KB

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Recall Acknowledgement

RCAK-23V168-1558.pdf 692.15KB

 


Defect Notice 573 Report

RCLRPT-23V168-8458.PDF 213.893KB

 


Miscellaneous Document – Chronology of Defect / Noncompliance Determination

RMISC-23V168-6445.pdf 71.966KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V168-6781.pdf 53.21KB

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Recall Quarterly Report #1, 2023-1

RCLQRT-23V168-7430.PDF 211.136KB

 


Recall Quarterly Report #2, 2023-2

RCLQRT-23V168-1839.PDF 211.237KB

 


Recall Quarterly Report #3, 2023-3

RCLQRT-23V168-9833.PDF 211.459KB

 


Recall Quarterly Report #4, 2023-4

RCLQRT-23V168-5545.PDF 211.566KB

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V168&docType=RCL

 


 

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