Powerboost Hybrid Battery Failure

[rryerso]

My 2021 F150 Limited ran without issue to
30K miles. About 5 months ago experienced
the "Stop Safely Now" message when I
attempted to start. Truck locked in park.
After a couple of hours it started up
without error. It happened again a month
later. Eventually it started. 3 weeks ago
it happened a 3rd time and stayed in
error.. Powerboost will only start and release
park if the hybrid battery is working.
Under warranty I called Ford and they
sent a tow truck. Literally dragged my
truck up on the flatbed. Towed to a
local Ford dealer who had to replace the
hybrid battery and connectors that
were burnt! Fuel tank had to be removed
ti do the work. Took 2 1/2 weeks waiting
for parts. I havent heard of this happening.
Tryck is running great now.

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[DT444T]

Damn. I'm almost at 60k and this is the first failure I've heard of. Sorry to hear and sorry for the frustration. I'm glad Ford got it fixed and now you have a newer battery.

 

[rryerso]

My 2021 F150 Limited ran without issue to
30K miles. About 5 months ago experienced
the "Stop Safely Now" message when I
attempted to start. Truck locked in park.
After a couple of hours it started up
without error. It happened again a month
later. Eventually it started. 3 weeks ago
it happened a 3rd time and stayed in
error.. Powerboost will only start and release
park if the hybrid battery is working.
Under warranty I called Ford and they
sent a tow truck. Literally dragged my
truck up on the flatbed. Towed to a
local Ford dealer who had to replace the
hybrid battery and connectors that
were burnt! Fuel tank had to be removed
ti do the work. Took 2 1/2 weeks waiting
for parts. I havent heard of this happening.
Truck is running great now.

The warranty work cost to the dealership was about $3500.00. I was told the cost without warranty would be about $8500.00. Regen on the new battery increased from 94% to 100%. A shoutout to Castle Rock Ford CO who provided me a 2023 F150 Lariat as a loaner during the downtime. Great dealership. A Ford representative tracked the parts and repair. Phoned me every few days with an update.

 

[Snakebitten]

The battery assembly retails for $2000. (it's not a large battery)
I wonder why the repair would be estimated to be $8500?

 

[rryerso]

Not sure. That no warranty estimate sounded
inflated to me.

 

[Ajzride]

The battery assembly retails for $2000. (it's not a large battery)
I wonder why the repair would be estimated to be $8500?

Man that is tiny... looks so easy to make a bigger one

 

[Snakebitten]

Man that is tiny... looks so easy to make a bigger one

And everything you see in that Pic is not even the actual 1.5KW cell pack.
The cell pack itself is underneath all the BMS hardware, nestled in the coolant channel-framework.

Bottom side:

 

[Snakebitten]

Most of that $2000 is not for the actual 1.5KW battery itself, but rather all the electronics you see managing the current of the little battery.

Arguably Ford doesn't have but $200 in the Powerboost battery cells themselves?

 

[JExpedition07]

Most of that $2000 is not for the actual 1.5KW battery itself, but rather all the electronics you see managing the current of the little battery.

Arguably Ford doesn't have but $200 in the Powerboost battery cells themselves?

Unfortunately that can be said for most any part on a car. I doubt Ford has much more than $100 into a tow mirror. They sell them retail for $2,000.

 

[Samson16]

Powerboost will only start and release

I was told the cost without warranty would be about $8500.00.

Perhaps because our warranty is for 10 years/ 100,000mi, and being an expert in inflationary economics, when the HVB is finally out of warranty that will be the cost. ?

 

[UGADawg96]

And everything you see in that Pic is not even the actual 1.5KW cell pack.
The cell pack itself is underneath all the BMS hardware, nestled in the coolant channel-framework.

Bottom side:

So crazy all that is needed for the powerboost batteries since they are so small ?

 

[Snakebitten]

So true. It'd be almost in indiscernable if that battery back housed twice the battery. Maybe 2" thicker? Another $200

Would love the additional regen potential.

 

[Gros Ventre]

Based on my experience with the Escape Hybrid I remarked to my dealer shortly after delivery that the battery pack needed to be about twice the size of the OEM installed pack... Maybe more. I get about 0.8 miles level on the battery. In my Escape Hybrid, when new, I got about 2.5 miles That was a pack made up of D-cells (Ni MH) assembled to produce 330VDC.

 

[Bob Violence]

So crazy all that is needed for the powerboost batteries since they are so small ?

Reminds me of the fake SNL commercial for the Mercedes AA Class.

https://www.nbc.com/saturday-night-live/video/new-mercedes/3021121

 

[RGrove]

Hybrid batt issues are how I found this forum... I've been getting hybrid battery faults since probably 40k (immediately after warranty expired), but never a "stop now" warning.
I'd get "Generator is overloaded" faults, "Service vehicle soon", and a CEL with code P0B24. "Service Vehicle" and CEL always together, and "Generator..." warning would only come on with the other two. Electric drive is completely disabled when the faults occur.
These were originally always at a cold startup. Sometimes I could manually clear it by shutting the truck off and waiting 3 minutes, with the CEL remaining for a few more starts, then clearing itself. Then randomly occur again soon after.

I had the truck in for 60k service interval (late, at 70k), and asked for them to address this. Service writer gave the truck back and said they "reprogrammed the battery" instead of replacing it. I'm almost thinking they added some kind of diag software to stress test it, because now the faults are constant and worse than ever. I'd get a startup without a fault and think, "Hey, maybe I'll get electric this drive" and then the fault would trip after almost a mile on the electric odo. I'd really like my truck to run great again, too...

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