While trying to fix one problem, plant workers may have caused another by forgetting to replace a bolt in the F-150 Lightning’s battery pack
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There are few feelings worse than trying to fix one issue and causing another, but that’s exactly what Ford is going through in a new recall that affects the 2023 F-150 Lightning. A nut may have been removed during a factory rework operation, leading to an increased fire risk in the high-voltage battery system.
The issue came to Ford’s attention in December when it received a field report regarding a 2023 model experiencing power loss while on the road. The driver was unable to restart the pickup, prompting its return to the dealership.
Upon inspection, technicians discovered that the high voltage battery junction box was missing a nut. They reported their findings to Ford’s Critical Concern Review Group, which conducted an investigation. It was determined that the fastener had been inadvertently removed during an unrelated rework operation at the factory.
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If the nut holding the battery bus bar is loose or missing, it can lead to an area of high resistance that causes arcing, and can trigger diagnostic trouble codes in the F-150 Lightning, ultimately shutting it down. In a worst case scenario, it could lead to a battery fire. Fortunately, Ford is not aware of any accidents or injuries relating to this problem.
To remedy the issue, Ford is launching a recall, and will reach out to owners on March 18. They will be asked to take their vehicle to a nearby dealer, where the high voltage batter junction box bus bar will be inspected, and all fasteners will be tightened to spec. Any other damage caused by this issue will also be repaired at no cost to the owner.
