24S11 – High Voltage Battery Junction Box Bus Bar Retention Nut Inspection – 2023 Ford F-150 Lightning

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February 23, 2024 NHTSA CAMPAIGN NUMBER: 24V144000

Improperly Secured Battery May Cause Fire

Electrical arcing increases the risk of a fire. In addition, a loss of drive power may occur, which can increase the risk of a crash.

 

NHTSA Campaign Number: 24V144000

Manufacturer Ford Motor Company

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 216

 

Summary

Ford Motor Company (Ford) is recalling certain 2023 F-150 Lightning vehicles. The fasteners that secure the junction box bus bars inside the high-voltage battery pack may not have been tightened securely, which can cause electrical arcing at the busbars.

 

Remedy

Dealers will inspect and repair the busbar fasteners and replace any damaged components as necessary, free of charge. Owner notification letters were mailed on March 22, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 24S11.

 

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

 


February 26, 2024

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD
Safety Recall 24S11
Certain 2023 Model Year F-150 Lightning BEV Vehicles
High Voltage Battery Junction Box Bus Bar Retention Nut Inspection

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
F-150 Lightning BEV 2023 Rouge Electrical Vehicle Center October 31, 2022 through August 02, 2023

US population of affected vehicles: 215. Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, there may be missing or loose retention nuts on the high voltage battery junction box bus bars in the high voltage battery pack. Electrical arcing may occur, which can increase the risk of fire. In addition, a “Stop Safely Now” message may occur in the instrument cluster followed by loss of motive power.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the high voltage battery junction box bus bars for missing or loose retention nuts. Dealers will also confirm proper torque of all eight bus bar retention nuts.

If any bus bar retention nuts are found missing or loose the customer should be put in a rental vehicle until final repair instructions are available. Parts are expected to be available Q2 2024.

This service must be performed on all affected vehicles at no charge to the vehicle owner. For new vehicle storage guidelines, refer to EFC13033, Storage Guidelines for New Vehicles.

To assist vehicle owners to have this repair completed when parts are available, dealers should:

  • Arrange to pick up the owner’s vehicle and drive it to the dealership for repairs (rentals are authorized – see Rental Vehicles) o Re-deliver the owner’s vehicle after repairs have been completed.
  • Pick-Up & Delivery should be made available for all customers. Refer to the Rental and Claiming sections for further details.

 

ESSENTIAL SPECIAL SERVICE TOOLS

If you do not have the special tools needed, please contact 1-800 ROTUNDA and choose option 3 to place an order to purchase.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of March 18, 2024. 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 $27,168 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

MOBILE SERVICE REPAIR ASSESSMENT LEVEL

  • All repairs in this program have the following assessment level.:

– Not a Mobile Service Repair

 

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.

 

BRANDED / SALVAGED TITLE VEHICLES

Affected branded / salvaged title 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 PO Box 6251, Dearborn, MI 48121-6251.
  • 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 missing or loose high voltage battery junction box bus bar retention nuts.

 

RENTAL VEHICLES

Dealers are pre-approved for up to 30 days for a comparable 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 30 rental day(s) is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.

 

PICK-UP & DELIVERY- Participating Dealers

Dealers participating in the Remote Experience Program:

  • Ford Dealers – Refer to EFC14125, 2024 Remote Experience Program, Pick-Up & Delivery Offset section for additional details.

 

PICK-UP & DELIVERY- Non-participating Dealers

Ford Dealers not participating in the 2024 Remote Experience Program for Pick-Up & Delivery are authorized to claim unique services for completing this program.

  • Dealers are authorized to claim one-half labor hour per repair for vehicle Pick-Up & Delivery services. Refer to Labor Allowances for details.
  • Dealers must retain a Vehicle Pick-Up & Delivery Record with the repair order documentation.

 

PARTS REQUIREMENTS

Part Number  Description Order Quantity
VC-13DL-G Motorcraft Yellow Prediluted Antifreeze/Coolant (Up to

15.9 Liters per vehicle)

As Required

 


CERTAIN 2023 MODEL YEAR F-150 LIGHTNING BEV VEHICLES — HIGH VOLTAGE BATTERY JUNCTION BOX BUS BAR RETENTION NUT INSPECTION

SERVICE PROCEDURE

IMPORTANT: This Field Service Action (FSA), must be performed by a certified BEV technician.

IMPORTANT: This procedure was modified from the original Workshop Manual (WSM) procedure. Follow technical instructions carefully.

NOTE: If you do not have the special service tools referenced in the Workshop Manual to perform the Field Service Action repair, please contact 1-800-ROTUNDA and choose option 3 to place an order.

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.

1. Remove the High Voltage Battery (HVB) Cover. Follow the procedures in Workshop Manual (WSM) Section 414-03A.

2. Disconnect the Battery Energy Control Module (BECM) electrical connectors in the sequence shown. See Figure 1.

NOTICE: The BECM electrical connectors must be disconnected in the sequence shown or component damage may occur.

 

NOTICE: Wait 10 seconds after disconnect the BECM electrical connector shown, See Figure 2, before disconnecting the remaining electrical connectors or component damage may occur.

3. Disconnect the BECM electrical connector. See Figure 2.

 

NOTICE: The BECM electrical connectors must be disconnected in the sequence shown or component damage may occur.

4. Disconnect the BECM electrical connectors in the sequence shown. See Figure 3.

For Standard Range Batteries – Continue to Step 5.

For Extended Range Batteries – Continue to Step 15.

 

STANDARD RANGE BATTERIES

5. Open the terminal covers and remove the bolts. See Figure 4.

Torque: 119 lb.in (13.5 Nm)

6. Remove the bus bar. See Figure 4.

7. Install the battery module terminal covers. See Figure 4.

 

8. Open the terminal covers and remove the bolts. See Figure 5.

Torque: 119 lb.in (13.5 Nm)

9. Remove the bus bar. See Figure 5.

10. Install the battery module terminal cover. See Figure 5.

 

11. Open the terminal cover and remove the bus bar nut. See Figure 6.

Torque: 106 lb.in (12 Nm)

12. Open the terminal cover, remove the bolt and the bus bar. See Figure 6.

Torque: 119 lb.in (13.5 Nm)

13. Install the battery module terminal cover. See Figure 6.

14. Continue to Step 24.

 

EXTENDED RANGE BATTERIES

15. Open the terminal covers and remove the bolts. See Figure 7.

Torque: 119 lb.in (13.5 Nm)

16. Remove the bus bar. See Figure 7.

17. Install the battery module terminal covers. See Figure 7.

 

18. Open the terminal cover and remove the bus bar nut. See Figure 8.

Torque: 106 lb.in (12 Nm)

19. Open the terminal cover, remove the bolt and the bus bar. See Figure 8.

Torque: 119 lb.in (13.5 Nm)

20. Install the battery module terminal cover. See Figure 8.

 

21. Open the terminal cover and remove the bus bar nut. See Figure 9.

Torque: 106 lb.in (12 Nm)

22. Open the terminal cover, remove the bolt and the bus bar. See Figure 9.

Torque: 119 lb.in (13.5 Nm)

23. Install the battery module terminal cover. See Figure 9.

 

ALL VEHICLES

24. Using a voltage meter drain both High Voltage Battery Junction Boxes to zero. Place the negative probe on the battery case. Touching the terminals will drain the capacitors. See Figure 10.

 

25. Check the residual torque-to-tighten on the bolts in Figure 11. Record the data.

Torque-to-tighten: 7.5 Nm (66.4 lb.in) to 13.8 Nm (122.1 in.lb)

NOTE: Make sure to record the data based on the numbers in the figure below.

 

26. Remove the nuts and the bus bar. See Figure 12.

Torque: 106 lb.in (12 Nm)

 

27. Check the residual torque-to-tighten on the bolt in Figure 13. Record the data.

Torque-to-tighten: 7.5 Nm (66.4 lb.in) to 13.8 Nm (122.1 in.lb)

NOTE: Make sure to record the data based on the number in the figure below.

 

28. Were any bus bar fasteners (excluding fastener #6) from steps 25 or 27 missing or not pass the torque check?

No – Reassemble vehicle by reversing steps 1-26.

Yes – Reassemble the vehicle by reversing steps 1-26. Vehicle CANNOT be driven and should not be returned to customer. Customer should be offered a rental vehicle until the final repair is available.

 

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Ford Motor Company (Ford) Recall No. 24S11 Chronology

CERTAIN 2023 MODEL YEAR F-150 LIGHTNING VEHICLES – HIGH VOLTAGE BATTERY BUS BAR RETENTION NUTS LOOSE OR MISSING

Date of Submission: February 23, 2024

Chronology of Defect / Noncompliance Determination

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

On December 14, 2023, Ford’s Critical Concern Review Group (CCRG) opened an investigation into a field report and an associated warranty report for a 2023 model year F-150 BEV that came to a stop and would not restart. The reports indicated that the dealership found a missing nut on the high voltage (HV) battery bus bar that is affixed to the High Voltage Battery Junction Box, also referred to as the Bussed Electrical Center (BEC), within the HV battery pack.

Engineering evaluated the returned parts and confirmed that the damage was consistent with the missing nut. The missing nut caused an area of high resistance resulting in arcing at the joint which triggered diagnostic trouble codes (DTCs) disabling the HV system. The DTCs resulted in loss of motive power without restart.

The CCRG reviewed plant process records at the high voltage battery assembly facility to determine if installation of a retention nut could have been missed during the assembly process. All bus bar joints in the BEC assembly are secured during initial assembly using Direct Current (DC) nut runners with torque and angle verification. The CCRG investigation determined that a bus bar retention nut was potentially removed in error during a rework operation for an unrelated issue. Ford records show that the high voltage battery assembly for the subject vehicle of the warranty/field report went through a rework operation on March 15, 2023. There was no additional verification of retention nut torque during the remainder of the assembly process. The impacted vehicle population consists of batteries that were (a) built from February 1 through March 31, 2023 and (b) reworked and reintroduced to the assembly line after the BEC fastener rundown operation.

As of February 14, 2024, Ford Motor Company is aware of one field report (received September 18, 2023) and one warranty report (received October 9, 2023) related to this concern, both for the same incident.

On February 16, 2024, 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

 


5 Associated Documents

Chronology of Defect / Noncompliance Determination

RMISC-24V144-0704.pdf 62.906KB

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Manufacturer Notices(to Dealers,etc)

RCMN-24V144-8577.pdf 2389.371KB

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Recall Acknowledgement

RCAK-24V144-7507.pdf 676.633KB

 


Defect Notice 573 Report

RCLRPT-24V144-5392.PDF 215.547KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-24V144-8825.pdf 54.706KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V144&docType=RCL

 


 

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