P0AFA on Ford

The C-Max hybrid battery pack (lithium-ion in Energi, NiMH in Hybrid) can exhibit cell imbalance and capacity degradation, triggering the "Stop Safely Now" warning message. This disables the hybrid system and forces the vehicle into a reduced-power limp mode. The Energi plug-in version's lithium pack generally holds up better than the base Hybrid's NiMH cells. Ford's 8-year/100,000-mile battery warranty covers most failures, but out-of-warranty replacement is costly.

Certain 2020-2024 Escape Plug-in Hybrid (PHEV) vehicles have a manufacturing defect in one or more high-voltage battery cells (Samsung SDI supplied) that can cause an internal short circuit. When it occurs, the vehicle displays a 'Stop Safely Now' message, can lose motive power while driving, and the battery can experience thermal venting that may lead to a vehicle fire. Because a fix was not initially available, Ford advised affected PHEV owners to stop plugging in and charging to keep the battery at a lower state of charge and reduce fire risk. This issue is distinct from the earlier 2.5L hybrid engine-block-breach fire recall — it is specifically the PHEV traction battery pack. The defect prompted follow-on recall activity (e.g., 26V091) covering additional 2023-2025 Escape PHEVs.

Certain 2022-2024 F-150 Lightning EVs (built March 16, 2022 through August 14, 2024) have high-voltage battery cells from SK Battery America with a manufacturing defect that can misalign internal electrodes. The cathode aluminum tabs may contact the anode material, causing an internal short circuit when the pack is at a high state of charge. Over repeated charge/discharge cycles this can lead to a battery fire without warning. At the time of filing Ford was aware of 5 reported fires and 1 injury under investigation. This is a Lightning-specific high-voltage battery issue, separate from the earlier loose battery-junction-box nut recall.

Select 2025 F-150 PowerBoost (3.5L V6 full hybrid) trucks built between January 30 and February 5, 2025 were assembled with an incorrect fuse in the high-voltage battery junction box. The wrong fuse can fail, resulting in a sudden loss of drive power while driving, which increases crash risk. This is specific to the PowerBoost hybrid's high-voltage electrical system and is separate from the conventional 12V/electrical complaints on gas-only trucks.

Many Ford F-150 Lightning owners report persistent issues with DC fast charging, including charge fault errors, unexpectedly slow charging speeds, and sessions that terminate prematurely. Some vehicles charge at only 40-70kW at stations rated for 150-350kW. The charging speed often drops dramatically after 2-5 minutes at a fast charger, settling well below the advertised 150kW peak rate. The battery charging control module (BCCM) can develop faults that prevent DC fast charging entirely, displaying an orange charge ring and "Vehicle Charging Fault" errors. Ford has released software updates to improve charging performance, but many owners continue to experience issues.

The retention nuts securing the high-voltage junction box bus bars inside the traction battery pack may be loose or missing due to an assembly/torque error, which can cause electrical arcing at the busbars, increase fire risk, and trigger a sudden loss of drive power (often preceded by a "Stop Safely Now" message). This is distinct from any battery-cell defect — it is a workmanship problem on 2023 Lightnings built at the Rouge EV Center from Oct 31, 2022 through Aug 2, 2023. Ford recalled the affected trucks (24S11 / NHTSA 24V144000, later expanded as 25V272000).

Ford Fusion Hybrid spans two generations with different high-voltage batteries — degradation patterns differ. 1st-gen 2010-2012 (NiMH, ~1.4 kWh): typical degradation appears at 100,000-150,000 miles with reduced EV-mode range and increased ICE intervention. Replacement runs $2,500-$4,000 at independent hybrid specialists. 2nd-gen 2013-2020 (Lithium-ion, ~1.4 kWh): better thermal management has led to longer life on average but cell imbalance issues appear at 150,000+ miles. 'Stop Safely Now' warnings often precede full failure. 2013-2020 Energi PHEV variants share the architecture but with larger 7.6 kWh batteries — separate degradation curve. Owners should check cell balance via OBD-II scanner with hybrid module support (Forscan recommended).