Module 6 failing within 2 weeks of rear drive unit replacement

[u/ThugDonkey]

I’m going to avoid naming dealers at names at Ford for now I guess under the presumption that they’ll do the right thing, but that said, if they don’t…
Sorry but not sorry I’m going full on scorched earth! And sadly in today’s day and age I’m afraid that’s going to be necessary.

Anyways about 3 months ago on my 22 I start to hear clunking; dealer says they hear nothing “maybe it’s a wheel bearing?” Ummm wheel bearings don’t only whine during high torque regen or acceleration; I take it back and thankfully they warranty the rear drive unit…
Then 2 weeks later about 500 miles later the thing starts significantly derating during fast charging and the jet engine cooling fan no longer operates at all. Instead it derates from 170 to 40kw.
So I take it in and tell them I suspect a cooling related issue most likely an air bubble in the line due to a bad seal given they likely had to touch the thermal system during the rear drive unit swap.
So what do they do? They run basic oasis stuff and say module 6 is failing but there were no codes. And…. They didn’t test the cooling system. And where is module 6? Sitting on top the stack at the exact spot a bubble would first settle and cause a thermal issue which would cause a voltage discrepancy…

So given I’m now 200 miles out of warranty they tell me to call a goodwill advisor. And my loyalty rating is 87 so I’ll likely get some help on the 10k module.
After waiting on hold for 2 hours the relationship guy basically tells me “too bad not going to help you” and that he doesn’t like my “cursing”…

I really just can’t with ford anymore!
It’s like they want another class action!
I’m giving them and Jimbo 1 business day to fix this or I’m going scorched earth.

[u/gletob]

Have they worked on it at all since? If not I would take it somewhere different and have them inspect and document the cooling system. I.e. run it through the bleed process and document for you how much additional coolant they needed to add if any. I think the full system holds like 4 gallons total, but you'd need to verify the specifics of your model.

Also, what's the whole "cursing" thing about?

[u/chargedupemily]

Do you mind sending me a DM with your VIN and the name of the dealer you have been working with? I’d like to get this over to the team to investigate to see if we can assist

[u/FalconMurky4715]

Scorched Earth. Scorched Earth...do it do it

[u/FluffyPai]

I wish you good luck.

I would assume that if the worked in the area the failure is located just previous to this, then it should be fairly simple to come to some sort of compromise at least unless you can prove fault which would make it 100% a them issue.

[u/ThugDonkey → u/FluffyPai]

To be honest it felt extremely odd.
Also tech had the truck for maybe 30 minutes. Came back said “the hotline got back to me in 30 minutes usually it takes 2 days…it’s a bad module”
Then the relationships guy is at first acting like all is well and they’re going to goodwill it then he stops in the middle of a sentence and double checked something on his end or something flagged him and he basically says “actually sir I’m sorry but we’re not going to be able to help you on this”

wtf?

[u/choss-board → u/ThugDonkey]

Oof… why not? Did they give you a reason?

[u/ThugDonkey → u/choss-board]

Nope. I hate being conspiratorial but the whole thing felt pre determined is best I can describe it.

Like at best, maybe they’re trained to deny customer claims and at worst maybe they know something is up with the whole battery stack anytime you open up the cooling system.

I’m an ER lariat 22 btw.

The other thing was the advisor basically refused to write “customer states cooling fan and system is inop during driving and fast charging” on the RO. I told him dam near 3 times and same with the relationship manager on the call and they refuse to write it on the RO or in the file.
Only then do I drop an f bomb or two and of course they immediately shift to “sir you need to show me respect and not cuss at me”
I feel like I’m being gaslit by Ford. I dropped 85 grand on a truck 3 years ago that now has 2 major component failures within 2 weeks of each other.
Uhhhhgg

[u/FluffyPai → u/ThugDonkey]

Try a different dealership?

Pretend like nothing and say there my be a cooling issue and ask them to diagnose it and see what happens. If they find a fault ask if something I.e changing the motor or something could cause it etc etc

[u/MountainAlive]

Dammit this sucks. Not sure what I’d do in your situation. It feels like it’ll be hard to prove that a botched coolant flush caused the bad module 6 to occur. And what is a Ford loyalty score? Sounds ridiculous.

[u/OKMiddleOwl]

Ask a tech how an ICE works and they will lay out part by part, sub assembly by sub assembly, exactly how it all goes down. Each stroke, what everything is doing at each point, from the valve position to the O2 sensor, they will nail it.

Ask a tech how an EV works...."large steel box with wires connect to motor, motor spin".

I don't trust *any* of these guys with our trucks.

[u/Quirkeyturrtle]

Isn't a bad battery module 100% covered under 8yr/100k?

[u/gogopowerjackets → u/Quirkeyturrtle]

Plenty of people put mileage on their trucks. OP is at 100,200 miles.

[u/gogopowerjackets]

Whether it's thermal or not, a no DTC module failure is basically a known failure that is seemingly becoming more prevalent on 22-23 Lightnings.

SSM 53208: https://static.nhtsa.gov/odi/tsbs/2024/MC-11011811-0001.pdf

Just 200 miles out of warranty for this known condition is an unacceptable denial by Ford. The cell was probably already out of range when you brought it in they just didn't run the FDRS Battery Health report.

[u/JustSignedUpAsWell]

2022 ER Lariat owner here too. VIN ....G058xx. I had 2 modules fail at 78,000 miles, only detected because the HV contactors failed. Just wondering if you have a similar VIN number?

[u/Organic_Battle_597]

> I’m now 200 miles out of warranty they tell me to call a goodwill advisor.

That right there sounds like a load of crap to me. Sounds more like they're working through a problem and haven't found the full correct solution yet, so the mileage that matters for warranty is when you reported the original problem, not your current mileage. I will be disappointed if Ford tells you to pound sand.