Ford 2022-2023 F-150 Lightning Battery Removal Owner’s Manual
- June 3, 2024
- Ford
Table of Contents
Ford 2022-2023 F-150 Lightning Battery Removal
Battery Removal Guide
Battery Removal Guide
High Voltage Battery Depowering
WARNING
THE HIGH-VOLTAGE SYSTEM MAY RETAIN A DANGEROUS LEVEL OF VOLTAGE FOR A SHORT
TIME AFTER THE SERVICE DISCONNECT HAS BEEN OPENED. WAIT 5 MINUTES FOR THE
VOLTAGE TO DISSIPATE BEFORE BEGINNING SERVICE. FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING
REMOVING THE BATTERY HIGH VOLTAGE SERVICE DISCONNECT DOES NOT DISSIPATE
VOLTAGE INSIDE THE BATTERY PACK. THE BATTERY PACK REMAINS LIVE AND DANGEROUS.
CONTACT WITH THE HIGH VOLTAGE BATTERY PACK INTERNALS MAY RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.
WARNING
ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH VOLTAGE SAFETY
SYSTEMS AND PRESENT A POTENTIAL HIGH VOLTAGE ELECTRICAL SHOCK HAZARD. EXERCISE
CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) INCLUDING
HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC JEWELRY, INCLUDING
WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY THE FORD
EMERGENCY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS
MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING
TO PREVENT THE RISK OF HIGH-VOLTAGE SHOCK, ALWAYS FOLLOW PRECISELY ALL
WARNINGS AND SERVICE INSTRUCTIONS INCLUDING INSTRUCTIONS TO DEPOWER THE
SYSTEM. THE TOTAL VOLTAGE OF THE VEHICLE HV BATTERY PACK MAY BE UP TO
APPROXIMATELY 450 VOLTS DC. THIS VOLTAGE IS PROVIDED THROUGH HIGH-VOLTAGE
CABLES TO ITS COMPONENTS AND MODULES. THE HIGH-VOLTAGE CABLES AND WIRING ARE
IDENTIFIED BY ORANGE HARNESS TAPE OR ORANGE WIRE COVERING. ALL HIGH-VOLTAGE
COMPONENTS ARE MARKED WITH HIGH-VOLTAGE WARNING LABELS WITH A HIGH-VOLTAGE
SYMBOL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.
WARNING
SERVICE OF THE HIGH VOLTAGE SYSTEM ON THIS VEHICLE IS RESTRICTED TO QUALIFIED
PERSONNEL. THE REQUIRED QUALIFICATIONS VARY BY REGION. ALWAYS OBSERVE LOCAL
LAWS AND LEGISLATIVE DIRECTIVES REGARDING ELECTRIC VEHICLE SERVICE. FAILURE TO
FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING
NEVER CONNECT THE SERVICE DISCONNECT WHEN A HIGH-VOLTAGE COVER IS REMOVED.
ALWAYS INSTALL THE COVER PRIOR TO CONNECTING THE SERVICE DISCONNECT. THE COVER
PREVENTS INADVERTENT CONTACT WITH THE HIGH VOLTAGE WHICH IS PRESENT AT SEVERAL
POINTS UNDER THE COVER. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
WARNING
DISCONNECT THE 12V BATTERY BEFORE SERVICING THE DIRECT CURRENT TO ALTERNATING
CURRENT (DC-AC) INVERTER OR ALTERNATING CURRENT (AC) POWERPOINT TO PREVENT THE
RISK OF HIGH VOLTAGE SHOCK. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN
SERIOUS PERSONAL INJURY.
NOTICE
Do not backprobe, splice or repair the high voltage (orange) wiring. Voltage
in the system is approximately 450 volts DC. Damage may occur to equipment
added to the system.
NOTICE
None of the High Voltage Traction Battery (HVTB) wiring should be tapped or
spliced to check for battery voltage (power), ground or signals.
NOTICE
Modification of Low-Voltage (LV) power & control wires connecting to the High-
Voltage (HV) battery system can damage or disable the HV Battery system. Do
not open or modify High Voltage battery pack High Voltage Battery Depowering
using FDRS Before beginning any service procedure in this manual, refer to
health and safety warnings. Failure to follow this instruction may result in
serious personal injury. To prevent the risk of high-voltage shock, always
follow precisely all warnings and service instructions, including instructions
to depower the system.
The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.
- Using the FDRS CARRY OUT the BECM — High Voltage System De-energizing and follow the on-screen instructions.
- Release the Connector Position Assurance (CPA) clip.
- The tab must be depressed prior to pushing the connector back in or damage to the connector may result. Depress the tab while pulling the connector until the hole is completely visible on the top of the connector.
- Insert a suitable tool inside the connector hole to prevent the connector from closing.
- Using the FDRS COMPLETE the BECM — High Voltage System De-energizing and verify the high voltage system has been de- energized.
WARNING
To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death
WARNING
Before beginning any service procedure in this manual, refer to health and
safety warnings in WSM Section 100–00 General Information. Failure to follow
this instruction may result in serious personal injury.
NOTICE
Manual De-energization should only be performed when a Ford-specific
diagnostic tool is not available.
NOTICE
Excessive use of this method may cause damage to electrical connectors.
NOTICE
To prevent the risk of high voltage shock, the high voltage battery cover must
not be removed if any of the following condition exist:
-
BECM DTC P0AA6:00 that has been diagnosed to be an internal fault with the high voltage Battery.
-
BECM Diagnostic Trouble Codes (DTCs) P0AA1:00 AND P0AA4:00 are present.
-
BECM Diagnostic Trouble Codes (DTCs) P0D0F:00 AND P0AA4:00 are present.
-
Disconnect the Electric Vehicle Supply Equipment (EVSE) from the vehicle charge port.
-
Turn the ignition ON without depressing the brake pedal (Accessory mode).
NOTE: -
A scan tool that is capable of performing a self-test on the BECM is required.
-
Using a scan tool perform BECM self test and record the Diagnostic Trouble Codes (DTCs).
-
If BECM Diagnostic Trouble Codes (DTCs) P0AA1:00 AND P0AA4:00 are present or Diagnostic Trouble Codes (DTCs) P0AA1:00 AND P0DOF:00 are present:
-
Refer to WSM procedures in section 414-03A High Voltage Battery, Mounting and Cables, Diagnosis and Testing.
-
Turn the ignition OFF.
-
Release the Connector Position Assurance (CPA) clip.
-
-
The tab must be depressed prior to pushing the connector back in or damage to the connector may result. Depress the tab while pulling the connector until the hole is completely visible on the top of the connector.
- Insert a suitable tool inside the connector hole to prevent the connector from closing.
- Disconnect the low voltage electrical connector at the High Voltage Battery.
- Disconnect the high voltage electrical connector at the High Voltage Battery.
- Wait a minimum of 5 minutes.
Battery Removal
NOTE
Before proceeding ensure the high voltage service disconnect procedure has
been preformed.
NOTICE
Enable the “Emergency Tow” feature to allow the vehicle to remain in neutral
while depowered.
-
De-energize the high voltage system.
-
Disconnect the battery negative terminal.
-
Remove the push pins and the underbody side covers.
-
Remove the screws and the underbody shield.
-
Remove the bolts and the skid plate.
-
Remove the bolt and position the ground wire aside.
-
Clamp the coolant hoses. Use the General Equipment: Locking Pliers
- Disconnect the coolant hoses.
- Disconnect the coolant hoses.
-
Install caps over the HVB coolant tube assembly openings.
-
Remove the bolts from the HVB cable bracket.
-
Disconnect the HVB electrical connectors.
-
Disconnect the HVB electrical connector retainers from the battery cable bracket and position the cables aside.
-
NOTICE
Only apply enough pressure from the powertrain lift table to contact and support the high voltage battery during the removal. Excessive pressure placed under the high voltage battery may cause damage to the high voltage battery. -
NOTICE
A powertrain jack with a nonslip mat must be used to prevent movement of the high voltage battery. -
NOTICE
Failure to extend the handle away from the powertrain lift table may cause damage to the high voltage battery when lowering.
-
-
Position the powertrain lift table under the HVB.
-
Extend the handle away from the powertrain lift table.
-
Remove the bolts from the HVB.
-
With the aid of an assistant, remove the high voltage battery.
SPECIAL NOTE TO DISMANTLERS AND SALVAGE YARDS
If a vehicle with a high voltage battery is to be scrapped, the high voltage battery must be disposed of following all local, state/provincial and federal guidelines.The vehicle’s Lithium-Ion High Voltage Battery pack (Li-Ion HVB) is fully recyclable and should be shipped to a permitted recycling facility. The guidelines below are for Li-Ion HVBs which have been removed from the vehicle and discharged.
General Packaging, Transport, and Recycling Guidelines
Once the battery has been removed from the vehicle and discharged:
- Store the battery components in a building or under shelter so that batteries are kept dry and not exposed to high temperatures.
- Protect battery components from damage (e.g. crushed or punctured).
- It is recommended to ask about the specific packaging requirements for battery shipments to the recycler who will be receiving the battery components in order to avoid inappropriate repacking/stacking of the batteries.
- Batteries should be sorted by type. Keep lead acid batteries, NiMH batteries, and Li-Ion batteries separated from each other (e.g. separate pallets or storage locations).
- Make sure the battery recycler is aware of the battery type. Li-ion batteries cannot be recycled in the same manner as lead acid or NiMH batteries.
Though Ford Motor Company makes no representations or endorsements, there are companies that have the capability to accept, consolidate and recycle undamaged Li-Ion HVBs, and a few are listed below. Contact the appropriate battery manufacturer for additional information.
North America Battery Recyclers
- Once the battery has been removed from the vehicle and discharged:
- Kinsbursky Brothers, Inc. 1125 Beacon Street Brea, CA 92801: Phone: (800) 502–9258
- Retriev Technologies, Inc. 265 Quarry Rd SE Lancaster, OH 43130: Phone: 740-653-6290
Applicable Laws/Regulations
The following is a general explanation of certain applicable laws; however,
these laws change from time to time, additional regulations are under
development and Ford Motor Company makes no representation that this is a
complete summary.
Packaging and Transport
Packaging and Transport The U.S. Department of Transportation (DOT) outlines
packaging and shipping requirements for Li-Ion batteries. Certain exceptions
on packaging and transportation regulations for large format Li-Ion batteries
may be found in 49CFR 173.185 (d) and (f). Make sure that the shipping
paperwork is filled out correctly and that the shipment is properly labeled
per federal, state, and local laws and regulations. Ensure that you are
complying with any record keeping requirements. Generally, under U.S. DOT
regulations, Li-Ion batteries are considered a dangerous good and regulated as
hazardous materials when transported. Li-Ion batteries are classified as Class
9 hazardous material. Only certified hazardous material shippers should offer
transport of a hazardous material. Batteries for recycling should be shipped
by ground or vessel only. Do not ship batteries for recycling by air.
NOTE
A damaged battery (one that is leaking electrolyte from the battery pack)
might need to be shipped as a hazardous waste. If you are transporting a
damaged battery, utilize a company that specializes in hazardous waste
transport and management. Ensure that you comply with all applicable hazardous
waste management laws and regulations.
Recycling
40 CFR 261 states that manufactured articles that yield extracts which exceed
one or more of the concentration limits of regulated listed constituents, or
meets the definition of ignitability, corrosivity or reactivity are defined as
hazardous wastes and must be disposed of in accordance with federal and state
regulations. Since there are many variations in the specific chemistry of Li-
Ion batteries, additional classifications may be necessary to determine if the
battery is a hazardous waste. It is the responsibility of the generator to
make this determination. Generally, under federal and state law, sealed, Li-
Ion batteries may be considered dry cell batteries and therefore may be
managed as a universal waste; damaged or leaking Li-Ion batteries may be
regulated as hazardous waste under federal and state regulations.
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