Ford Recalls F-150 Lightning Electric Pickup Truck Over Missing Solder Joint

First and foremost, pricing for the work-oriented Pro trim level shot up from the original $39,974 to $49,995 at press time for both the 2023 and 2024 models. Back in August, none other than Ford’s very own big kahuna admitted that charging – as opposed to filling up with gas – can be a challenge.

There’s also the matter of driving range. Although it’s advertised with up to 320 miles (515 kilometers) on a full charge of the larger of two available batteries, the F-150 Lightning rarely gets close to 300 miles (483 kilometers) before it needs to be recharged. By comparison, the Environmental Protection Agency lists the 700-horsepower F-150 Raptor R with 432 miles (695 kilometers) and the V6-engined version with no more than 576 miles (927 kilometers).

The biggest flaw of the F-150 Lightning, however, is that Ford still has quality-related issues. You can easily tell that Ford is on a different level altogether from the other two automakers comprising the Big Three in Detroit by looking at NHTSA recall data.

Speaking of which, guess which Ford nameplate has been recalled once again with feeling? NHTSA recall number 23V-688 lists 931 potentially affected electric pickup trucks produced for the 2023 model year from July 27 through August 30 of this year.

What’s the matter with said vehicles? On September 1, the Critical Concern Review Group was informed of a problem identified at the Ford River Rouge Complex where the F-150 Lightning is assembled. The problem in question started with a diagnostic trouble code for loss of communication with the cabin coolant heater.

In-depth investigation determined that the supplier didn’t solder one of three low-voltage connectors to the printed circuit board assembly. The missing solder joint results in either intermittent or no electronic cabin coolant heater function at all, which is a noncompliance in the eyes of the NHTSA. More specifically, an inoperative windshield defrosting/defogging system goes against federal motor vehicle safety standard 103.

BorgWarner is the supplier of the iffy module, which bears part number RL3H-18E64-BB in Ford’s parts system. As per a FoMoCo report, suspect modules were produced by the folks at BorgWarner on a secondary assembly line that didn’t have the right processes in place to prevent improper soldering.

BorgWarner may be a giant automotive and electric mobility supplier, but when you’re contracted by a cheapskate like Ford, there’s no denying that mistakes can and will inevitably happen on such a tight budget. As you might have guessed by now, owners of affected trucks will have the modules replaced with properly soldered ones at no charge whatsoever for the part or service tech’s labor.

Dealers have been informed of this blunder on October 16, whereas owners will be notified via first-class mail between November 6 and November 10. If any owner paid out of pocket to have the electronic cabin coolant heater replaced, which is nigh-on impossible because all suspect F-150 Lightning pickup trucks are still covered by warranty, they are eligible for reimbursement.