Ford was forced to suspend production of its F-150 Lightning electric pickup truck for over a month after a vehicle caught fire during a routine quality check. The automaker later revealed that the issue was related to the battery pack’s high voltage, but it did not disclose the root cause. However, the incident had also affected 18 F-150 Lightning trucks that had already been delivered to customers, forcing Ford to recall them.
The National Highway Traffic Safety Administration (NHTSA) has now published the recall notice, identifying the exact cause. The defect occurs when the battery is fully charged or almost fully charged, which may result in “an internal short circuit in the battery that could cause a fire.” The issue was caused by production process deviations at the supplier, where “the cathode aluminum tabs may contact the anode electrode material.”
Ford confirmed that the 18 recalled F-150 trucks were built between January 20 and January 26, 2023, at the Rouge Electric Vehicle Center. The company has already contacted the affected truck owners, instructing them to visit a dealer to replace the battery pack.
Since the recall is issued by the NHTSA, it only applies to trucks delivered to US customers. Canada’s Transport Canada has yet to publish a similar recall.
Ford worked with its battery supplier, SK On, to rectify the issue and resumed production on March 13, 2023. The automaker assured its customers that they take safety issues seriously and have taken the necessary steps to ensure the safety of all their vehicles.
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