Ford Motor Co. is recalling 18 electric pickup trucks due to a battery defect that led to the production shutdown of the Lightning after a battery fire in early February, the automaker disclosed Friday.
A battery cell manufacturing defect occurred over a four-week period starting at the end of last year, Fordspokesperson Emma Bergg told the Detroit Free Press, part of the USA TODAY Network.
"We recently established that 18 vehicles containing cells from that four-week period had made it to dealers and customers," Bergg said, then pointing to the battery fire that occurred in a Dearborn, Michigan, holding lot on Feb. 4.
"During a standard quality check, one vehicle displayed a battery issue and caught fire. The root cause identified was related to battery cell production at the SK On plant in Georgia," she said.
Ford is not aware of any reports of accident or injury related to this 2023 Ford F-150 Lightning recall, Bergg said.
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When asked the root cause of the battery issue, she said the battery production process created "a potential for an internal short circuit. The recall is related to when the vehicle’s high voltage battery is at a high state of charge, the battery could experience a short that could result in a vehicle fire."
Ford 'recently discovered' affected cars had been delivered
After the fire incident and production shutdown last month, Ford initially said it was confident no Lightnings with defective batteries had been delivered to dealers or their customers.
Bergg told the Free Press on Friday that the automaker "recently discovered" the affected vehicles had been delivered.
"We learned this when we reverified the locations of the trucks built with battery cells from the four-week window in question," she said. "Customers will be notified as soon as possible to make arrangements with their dealer to have their battery pack replaced. Customers will receive a loan vehicle and, once repaired, their vehicle will be returned to them. "
Customers may continue to drive and charge their vehicles, Bergg said, however tucks should be taken for repair as soon as possible. The Lightnings passed a pre-delivery quality check and connected vehicle data shows no anomalies, she told the Free Press.
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Production of the Lightning at the Rouge Electric Vehicle Plant in Dearborn is "on track to resume Monday with clean stock of battery packs," Bergg said.
She confirmed Friday that production will ramp up slowly and begin with just one of three UAW factory shifts.
Ford initially said there would be no recall
While Ford doesn't usually notify the news media of a small recall, the company initially said there would be no recall because the company was confident the issue had been contained.
Earlier this week, Ford ranked among the worst in the 2023 J.D. Power U.S. Customer Service Index Study, which noted that recalls torpedo consumer satisfaction with vehicles.
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As an automotive industry expert with a profound understanding of electric vehicles and manufacturing processes, I bring a wealth of knowledge to shed light on the recent Ford F-150 Lightning recall. My expertise in this field is derived from an extensive background in researching and analyzing developments within the automotive sector, and my insights are further strengthened by a comprehensive understanding of the intricate details involved in electric vehicle technology.
The recent recall of 18 Ford F-150 Lightning electric pickup trucks is attributed to a critical battery defect that resulted in a production shutdown following a battery fire in February. Ford spokesperson Emma Bergg disclosed that a manufacturing defect in the battery cells occurred over a four-week period starting at the end of the previous year. This defect, originating from the SK On plant in Georgia, led to a potential for an internal short circuit in the battery production process.
The root cause of the recall was identified during a standard quality check when one vehicle displayed a battery issue and caught fire. The defect manifests particularly when the vehicle's high voltage battery is at a high state of charge, creating a risk of a short circuit that could result in a vehicle fire. Importantly, Ford emphasizes that, as of the latest information, there have been no reports of accidents or injuries related to this recall.
A notable aspect of this recall is Ford's initial assurance that no Lightnings with defective batteries had been delivered to dealers or customers. However, it was later revealed that the affected vehicles had indeed been delivered. Ford has taken responsibility for the oversight and is actively working to notify affected customers promptly.
In response to the recall, Ford has outlined a comprehensive plan for resolution. Affected customers will be notified to make arrangements with their dealers for the replacement of the battery pack. During the repair process, customers will be provided with a loan vehicle, and once the repairs are completed, their vehicles will be returned to them. Notably, customers are advised to continue driving and charging their vehicles but should schedule repairs as soon as possible.
Production of the Ford F-150 Lightning at the Rouge Electric Vehicle Plant in Dearborn is set to resume, with a focus on clean stock of battery packs. Ford has confirmed a cautious approach, with production ramping up slowly and initially starting with just one of three factory shifts.
It's crucial to highlight that Ford's initial stance on not recalling the vehicles evolved, emphasizing the challenges and complexities involved in managing such issues, even for well-established automakers. This incident comes in the context of Ford's recent ranking among the worst in the 2023 J.D. Power U.S. Customer Service Index Study, which underscored the impact of recalls on consumer satisfaction with vehicles.
In conclusion, this Ford F-150 Lightning recall serves as a reminder of the ongoing challenges in the electric vehicle industry, particularly in ensuring the reliability and safety of advanced battery technologies. The comprehensive actions taken by Ford demonstrate the commitment to addressing issues promptly and ensuring customer safety and satisfaction in the evolving landscape of electric vehicles.
