Ford F-150 Lightning battery replaced after 234,000 miles — InsideEVs
The traction battery in an electric Ford F-150 Lightning pickup was replaced after it failed at 234,000 miles. As InsideEVs reports, the repair was shown in a video by the Out of Spec Renew channel. Only one module in the battery was faulty, but replacing it separately proved more difficult than installing another complete battery pack.
What is needed for the replacement
To remove the battery, the pickup was raised on a lift, the coolant was drained, the high-voltage cables were disconnected, and the fasteners were removed. In terms of the number of connections, this procedure may be simpler than removing an internal combustion engine, which has numerous hoses, wires, mounts, and connections to the transmission.
However, the main challenge is the weight of the traction battery. The standard 98 kWh F-150 Lightning battery weighs about 1,800 pounds. A hydraulic scissor lift was used to remove it safely. For comparison, the publication also cites the 63 kWh Hyundai Ioniq 5 battery, which weighs 815 pounds.
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Battery pack repair
After the battery was removed, a damaged connector and a cooling system hose were found on the pack being installed. They were replaced with parts from the old battery. Removing the battery cover, according to the publication's description, was technically uncomplicated but time-consuming because of the large number of bolts.
The battery was then reinstalled using the lift, the cables and cooling circuits were connected, and the system was filled with coolant. The vehicle also required a repair to its 12-volt battery, after which the pickup was ready to return to the road.
