Battery exploded!

[Mark S.]

or the extra cost.

It seems idiotic that Ford would purposefully put batteries in their vehicles it knows will result in a significant number of warranty claims to "save" money. It makes more sense to me that Ford was unable to obtain the batteries it intended to use during certain production runs and used whatever it could get its hands on to keep production going.

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[rocks]

It seems idiotic that Ford would purposefully put batteries in their vehicles it knows will result in a significant number of warranty claims to "save" money. It makes more sense to me that Ford was unable to obtain the batteries it intended to use during certain production runs and used whatever it could get its hands on to keep production going.

Who said Ford knew the batteries would fail? They have in too many cases. Would be interesting to know if the OP asked for an AGM battery or if the dealer did the right thing and installed one.

 

[Mark S.]

Who said Ford knew the batteries would fail?

I don't believe anyone knows that for sure. Just as no one knows that Ford decided to switch to cheaper batteries to save money. We're all speculating. I try never to attribute to malice what can be explained by incompetence.

 

[Robins21]

In my 25 years working in the automotive business mostly in new car dealers this is the first I have ever heard of a battery just exploding for no reason. Usually something causes it to explode, like a short, a defective alternator, hooking up jumper cables improperly. We also have a lead acid battery in our 21 BS/BB.

 

[coopny]

I can't speak to whether or not Ford properly accounted for it in the battery management system for the bronco sport, but between the tons of electronics in the car, the automatic stop start, and the headlights that start running fans the instant they're on and continue for some time after, I'm not surprised that newer BSes like mine came with an AGM battery.

The situation with the 2021s to me is unclear as I've heard people saying they've had both "lead acid" (regular auto batteries) and enhanced flooded batteries. EFBs are basically a middle step before AGM that can tolerate deeper cycles.

There's basically two possibilities, as I see it, with the batteries being SLA/EFB earlier on, and then AGM later:

1. Ford saw COVID era shortages on AGM, and decided that it was better to not let the battery be a restriction on keeping cars rolling off the line. They went for an EFB, which was the next best thing (superior for start/stop loads over a standard lead acid battery, but not as good as AGM) and deal with it in the 3yr/36k mile bumper-to-bumper.
2. Ford believed that an EFB could handle it, only for data over time to show that EFBs were failing at high rates early on and decided to switch to AGM.

It's impossible for me to say which is which as I don't work for Ford or a dealer. In the case of #1, the car and battery management system would have been programmed to work with both. In the case of #2, they may have programmed the cars earlier to accept AGM if installed, or it may have been in an update to the BMS. I really suspect #1 because invoices like the original poster showed only show the battery replacement effort, but that would be speculative.

In any case - the sign of what Ford considers the remedy is, IMO, seems clear. Within the bumper-to-bumper, Ford is not just replacing BSes that came with SLA/EFB batteries with SLA/EFB batteries (either thinking they're sufficient, or it's a cheaper replacement to hopefully outlast the remainder of the warranty). They're paying more to replace them with AGM.

If I were a BS owner without an AGM I wouldn't rush out to replace a working battery - but at the first sign of trouble (warning lights, slow start etc.) I'd go to the dealer or someone else for a battery test. And I'd definitely replace it with an AGM.

 

[Alfa 2407]

In my 25 years working in the automotive business mostly in new car dealers this is the first I have ever heard of a battery just exploding for no reason. Usually something causes it to explode, like a short, a defective alternator, hooking up jumper cables improperly. We also have a lead acid battery in our 21 BS/BB.

I suspect something battery specific, internal short? Resilience to low voltage situations? There are a number of reasons that could be leading to issues as coopny has explained in an excellent manner

 

[sajohnson]

Who said Ford knew the batteries would fail? They have in too many cases. Would be interesting to know if the OP asked for an AGM battery or if the dealer did the right thing and installed one.

The invoice shows that the core (OE battery) was AGM.

 

[rocks]

The invoice shows that the core (OE battery) was AGM.

I guess I'll keep my battery for a while.

 

[sajohnson]

I guess I'll keep my battery for a while.

I plan to keep ours as long as it's working.

There's nothing magical about AGM batteries -- they are essentially flooded lead-acid (FLA) batteries with absorbent material between the lead plates. They do have some advantages over FLA, but many of them do not apply in automotive use.

When our battery needs to be replaced, I'll probably get an AGM -- if the price difference isn't too great.

For anyone interested, there are 36 'electrical system' complaints at the NHTSA:
https://www.nhtsa.gov/vehicle/2021/FORD/BRONCO SPORT

Also see:
https://www.nhtsa.gov/vehicle/2022/FORD/BRONCO%2520SPORT/SUV/4WD
https://www.nhtsa.gov/vehicle/2023/FORD/BRONCO%2520SPORT/SUV/4WD

 

[tRex]

AGM is required for 90% of modern vehicles including the bronco sport. No need to change to an AGM as it already has one. Unless you wanted to switch to a different manufacturer, as the ford AGM seem to have a high failure rate.

What's a "modern" vehicle? What does "required" mean? My 2018 CR-V and 2021 Badlands must be in this other 10%because both came with a conventional battery. AGM is still lead-acid BTW, but it is a more efficient design.

 

[rocks]

What's a "modern" vehicle? What does "required" mean? My 2018 CR-V and 2021 Badlands must be in this other 10%because both came with a conventional battery. AGM is still lead-acid BTW, but it is a more efficient design.

I'm guessing he means vehicles like the BS that make all kinds of noises when you shut the engine off or open and close a door. Too many electric gizmos like fans for headlights, wifi, computer settings etc on continuous battery draw with the engine off.

 

[coopny]

I plan to keep ours as long as it's working.

Agree with this.

There's nothing magical about AGM batteries -- they are essentially flooded lead-acid (FLA) batteries with absorbent material between the lead plates.

An enhanced flooded battery is an enhanced flooded technology as an option between a flooded lead acid battery and AGM. There are glass mate separators throughout the wet battery.
In an AGM, glass mats absorb all of the electrolyte. This makes AGM batteries spill proof.

They do have some advantages over FLA, but many of them do not apply in automotive use.

Ford and other OEMs don't pay more money to use AGM (or EFB) batteries over standard flooded lead acid batteries for zero reason. And one of the big reason have been the increasing number of power draw gadgets (radios, phone chargers, screens for the instrument cluster, safety sensors and cameras, active grill shutters, etc.) that are coming into cars, all the while the EPA is demanding better fuel economy and to game the EPA test for an extra 1-2 MPG, you need automatic engine start/stop systems.

EFBs accept charge more rapidly than regular FLAs (they charge quicker while the engine is on), and they are able to tolerate more cycles than FLAs:

Studies approximate EFB batteries will provide 85,000 engine starts, compared to 30,000 starts from standard flooded product.

AGM builds on these advantages even more (an AGM charges 5x faster than an EFB).

One closing thought from my end: While I've heard about how there have been engines and their control modules and starters and what not have all been designed to account for engine start/stop systems, I imagine that this still has a negative impact on the lifespan of batteries. AGMs are intended to help cope with these with faster charge rates, storing more energy so they can tolerate repeated starts, etc., but at the end of the day the battery is a wear item. Driving styles and frequency probably matter a lot (someone who drives infrequently and then does a lot of stop/go city driving likely stresses the battery more; someone who does deliveries like Amazon Flex or DoorDash probably puts more stress on the battery, etc.)

I would imagine that I have automatic start/stop disabled on my vehicle that I am putting less stress on the battery of my vehicle, but time will be the true test on its longevity...

 

[rocks]

Agree with this.




An enhanced flooded battery is an enhanced flooded technology as an option between a flooded lead acid battery and AGM. There are glass mate separators throughout the wet battery.
In an AGM, glass mats absorb all of the electrolyte. This makes AGM batteries spill proof.



Ford and other OEMs don't pay more money to use AGM (or EFB) batteries over standard flooded lead acid batteries for zero reason. And one of the big reason have been the increasing number of power draw gadgets (radios, phone chargers, screens for the instrument cluster, safety sensors and cameras, active grill shutters, etc.) that are coming into cars, all the while the EPA is demanding better fuel economy and to game the EPA test for an extra 1-2 MPG, you need automatic engine start/stop systems.

EFBs accept charge more rapidly than regular FLAs (they charge quicker while the engine is on), and they are able to tolerate more cycles than FLAs:



AGM builds on these advantages even more (an AGM charges 5x faster than an EFB).

One closing thought from my end: While I've heard about how there have been engines and their control modules and starters and what not have all been designed to account for engine start/stop systems, I imagine that this still has a negative impact on the lifespan of batteries. AGMs are intended to help cope with these with faster charge rates, storing more energy so they can tolerate repeated starts, etc., but at the end of the day the battery is a wear item. Driving styles and frequency probably matter a lot (someone who drives infrequently and then does a lot of stop/go city driving likely stresses the battery more; someone who does deliveries like Amazon Flex or DoorDash probably puts more stress on the battery, etc.)

I would imagine that I have automatic start/stop disabled on my vehicle that I am putting less stress on the battery of my vehicle, but time will be the true test on its longevity...

Great post with great info on battery types and start/stop!
I can't see how some here say that start/stop doesn't hurt the battery. Starting an engine takes battery power. I've never used S/S in any vehicle I owned that had it. Not do to battery use but as an annoying option.

 

[sajohnson]

An enhanced flooded battery is an enhanced flooded technology as an option between a flooded lead acid battery and AGM. There are glass mate separators throughout the wet battery.
In an AGM, glass mats absorb all of the electrolyte. This makes AGM batteries spill proof.

Ford and other OEMs don't pay more money to use AGM (or EFB) batteries over standard flooded lead acid batteries for zero reason. And one of the big reason have been the increasing number of power draw gadgets (radios, phone chargers, screens for the instrument cluster, safety sensors and cameras, active grill shutters, etc.) that are coming into cars, all the while the EPA is demanding better fuel economy and to game the EPA test for an extra 1-2 MPG, you need automatic engine start/stop systems.

EFBs accept charge more rapidly than regular FLAs (they charge quicker while the engine is on), and they are able to tolerate more cycles than FLAs:

AGM builds on these advantages even more (an AGM charges 5x faster than an EFB).

One closing thought from my end: While I've heard about how there have been engines and their control modules and starters and what not have all been designed to account for engine start/stop systems, I imagine that this still has a negative impact on the lifespan of batteries. AGMs are intended to help cope with these with faster charge rates, storing more energy so they can tolerate repeated starts, etc., but at the end of the day the battery is a wear item. Driving styles and frequency probably matter a lot (someone who drives infrequently and then does a lot of stop/go city driving likely stresses the battery more; someone who does deliveries like Amazon Flex or DoorDash probably puts more stress on the battery, etc.)

I would imagine that I have automatic start/stop disabled on my vehicle that I am putting less stress on the battery of my vehicle, but time will be the true test on its longevity...

In post #24, I wrote:

"There's nothing magical about AGM batteries -- they are essentially flooded lead-acid (FLA) batteries with absorbent material between the lead plates. They do have some advantages over FLA, but many of them do not apply in automotive use."

Not all, but many. As in: being capable of being mounted in any position, even upside down; being able to literally 'take a bullet' and keep working (per Lifeline); and being able to be installed indoors or in the interior of vehicles. Higher current max. charge and discharge rates -- however, that only becomes a factor if the alternator can put out more current than the FLA or EFB can safely accept -- and/or if there is a huge load that requires more amperage than the battery can provide.

Those are advantages in some situations -- but not in a BS or other civilian vehicle.

As for the advantages that DO apply to our use, some are mentioned here:

From Crown, a respected mfr that sells both AGM and FLA batteries:
https://www.crownbattery.com/news/agm-vs-flooded-batteries-what-you-need-to-know

This is from Interstate:
https://www.interstatebatteries.com/blog/absorbed-glass-mat-enhanced-flooded-battery-whats-the-difference

Something Interstate says that I question is :

"A standard or traditional flooded battery is a lead-acid battery used to crank a car's engine and support standard accessories while the engine is running. If your car requires more than the usual power load, this battery might not suit your vehicle."

** The 'demand' and 'load' they refer to is typically handled by the alternator when the engine is running -- which is when most accessories are used. In any case, both Motorcraft batteries for the BS have the same reserve capacity.

Generally speaking, AGM batteries are better (but there are poor quality AGMs out there). Keep in mind though that the specs of the Motorcraft batteries that fit the BS are pretty similar:

* BHEF-48H6: 700 CCA; 120 min. reserve capacity
* BAGM-48H6: 760 CCA; 120 min. reserve capacity

So they have identical energy storage capability, and the difference in CCA is <10%.

See Motorcraft Battery Spec Chart: https://www.macheforum.com/site/attachments/motorcraft_battery_specification_chart-pdf.12361/

As for cost, I just did a quick search and the AGM was actually cheaper than the EFB! In some cases an AGM with similar specs may be a bit more, but the difference is not much.

Bottom line -- AGM = good. I plan to get an AGM battery when the OE battery fails. In post #24, I was mainly reacting to the posts by forum members who seem to think that installing an AGM will solve various electrical issues. The only problem it will solve is an existing bad/failing battery.

 

[coopny]

So for the fun of it, I decided to search owners manuals and see what the specified battery was for the 2.0L EB in the BS by year.
2021 Bronco Sport - BHEF-48H6. No alternate.
2022 Bronco Sport - BHEF-48H6, alternatively BAGM-48H6-760
2023 Bronco Sport - BEF-48H6-A, alternatively BAGM-48H6-760
2024 Bronco Sport - BEF-48H6-A , alternatively BAGM-48H6-760

So all BSes at a minimum should have an EFB... if not an AGM. My 23 BS BL came with an AGM from the factory.

In terms of advantages applicable to cars, this other interstate link covers many. An AGM battery can drain by 80% and still crank the engine; a flooded battery is 50%. AGM batteries have more than 60,000 starts, more than 3x a standard flooded battery. AGM batteries charge 5x faster than flooded batteries.

If you defeat the auto start/stop (either by use of the button manually, an auto start/stop eliminator [hardware or FORscan programming], or keeping a small load like an LED nightlight on the A/C inverter), most of these advantages would be negated.

EDIT: For drivers that make short trips or don't drive daily in particular, the reduced self-discharge and increased charge rates, combined with the ability to start the vehicle at a much lower battery charge, can be beneficial. These can be mitigated by the use of a battery tender if one's parking situation (e.g. covered garage) permits it, but some people don't have access to electrical outlets where they park.)

I would note that there are some cycle loads on engine off that persist, namely the fans run for the headlights for some time after they turn off. There's also standby load from the radio and from the Fordpass telematics modem (although in theory, when working properly, the battery management system would disable both of those at a certain threshold to ensure they did not drain the battery to the point of the vehicle not starting).

Bottom line -- AGM = good. I plan to get an AGM battery when the OE battery fails. In post #24, I was mainly reacting to the posts by forum members who seem to think that installing an AGM will solve various electrical issues. The only problem it will solve is an existing bad/failing battery.

Agreed, a battery is one cause of electrical issues, there can be others. If I had random electrical issues with no explanation, based on how many times I've seen here about electrical gremlins and then "it was the battery", my first stop would be to the dealer, an auto parts store, or mechanic to run a load test on the battery to determine if it had failed. If it did, I would replace it with an AGM.

(Pretty much every other source for batteries except Ford only recommended an AGM replacement for my car; Autozone recommended both an EFB and an AGM as compatible for the exact same price of $249.99. Priced out a few sources to see who would likely have the cheapest battery replacement when the time does come, which hopefully isn't for 5+ years.)

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