Ford Authority

Ford F-150 Lightning Battery Pack Structure Analysis: Video

Sandy Munro and his team have already spent plenty of time tearing into the Ford F-150 Lightning. They’ve praised the electric pickup for its body-in-white (BIW), its battery thermal system, its chassis, and its frunk. Now, Munro & Associates have created a detailed video regarding their thoughts on the EV pickup’s battery pack structure.

Kevin Harty, a senior engineer with Munro & Associates, leads this deep dive into the Ford F-150 Lightning battery structure. He notes that the overall construction is similar to that of the Ford Mustang Mach-E. He points out its very large covering and seal for the fasteners to keep unwanted debris and moisture out. The battery pack itself exhibits a “two-tier” strategy, with walls for each cell.

The high-voltage connections are piped through an injection-molded component, which isn’t a bad strategy, per se, but Harty says that this casting process can create excess fasteners and seals that aren’t necessary for every application. The battery walls themselves are completely encapsulated, and Harty points out that the bulkheads on this application don’t quite line up with the walls. His could be because of costs, or it could be a design choice to mitigate the potential negative effects of a side impact to the F-150 Lightning.

Harty points out that Ford elected to use extruded posts that are welded in with one-sided access, which is a “simple, cheap and elegant setup” to provide ample space for the modules themselves. However, from a structural perspective, but if an issue were to occur with the modules, there could be a cascading effect throughout the entire pack – “similar to the Titanic and its waterproof bulkheads,” Harty says.

Harty says the Ford F-150 Lightning battery execution is fairly simple, and while there may be some room to improve things, there isn’t anything in particular that makes it a poor design. Give it time, and The Blue Oval will likely work out the kinks.

We’ll have more on the F-150 Lightning soon, so be sure and subscribe to Ford Authority for the latest Ford F-Series newsFord F-150 newsF-150 Lightning news, and comprehensive Ford news coverage.

Alexandra is a Colorado-based journalist with a passion for all things involving horsepower, be it automotive or equestrian.

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  1. Bob

    I read this battery pack costs $35,000 to replace. The author of an article stated he went to the Ford parts catalog to see what the replacement cost is for the Lightning. If true, people better do their homework before purchasing. Yikes !!

    1. TB

      The battery is covered by an 8 year/100,000 mile warranty. It’s going to be some time before anyone has to come out of pocket to replace a battery. Nobody has a crystal ball to see what prices will be 8 years from now. Homework assignment done.

      1. Bob

        That’s good news if you are interested in the electrification era. I still have concerns about the electric grid and how we charge millions of new electric cars every night.

        There is a company in Squamish, British Columbia that has developed a process of capturing CO 2 from the atmosphere. They have a building that looks like a large cooling tower. It draws in the air, refines the carbon out of the atmosphere, combine it with hydrogen (from water) and create a new liquid fuel. Any current vehicle on the road can be made carbon neutral without any modifications. Instead of pumping fuel as we know it, you pump this carbon neutral fuel into the same tank. The cost per gallon is the same as gasoline today. The pumps at gas stations do not need to be altered.
        It can be used with trucks, jets, tractors, etc…. There was a special on HBO and you can find a five minute video on the story. It seems like a viable alternative to an all or nothing mentality with electric.

        1. StatisticsGuy

          If there’s vehicle to home, it actually helps the grid. Most of the grid goes down due to AC demand. If your vehicle can power your home, guess who wins for time of charge plans? Not only that but it only happens that way because peaker plants are horrendously expensive to start up and take time to ramp up. Home battery supports America. Gas supports OPEC which is a cartel and supports middle east.

    2. StatisticsGuy

      That won’t be for roughly 10 years. I guarantee you spend more than 4k on gas and maintenance a year. Electric drive train is no maintenance and the battery is like buying ~8 years worth of fuel all at once.


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