I worked on bringing the assembly lines into production for both the frame and the battery sub frame, I'm pretty happy to hear they are happy with the weld quality

Ford is really in the plumbing business

Never mind the welds, it's a plumbing nightmare!😁

Love you guys so much. Thank you for inspiring both real and would-be engineers!

These videos are so well made. What an incredible job Munro team is doing.

Saw my first Lightning yesterday, looks even better up close, owner loves it. Strong first effort by Ford, clearly committed. Imagine future efforts will have fewer compromises

Fantastic review and assessments between Rivian and Ford. Pushing the industry to simplify manufacturing processes. Everyone benefits. Thank you guys!

Thank you Jordan and Kevin - excellent engineering analysis!

Another great overview and Engineering Analysis by the incomparable Munro Team! YOU GUYS ROCK!! We know why you have over 330 K. Subs and fans...🥰

Great job and intel! Every time I watch a video in this series I get excited for my Lighting later this year.

Brilliant video guys. Munro are very generous in sharing their engineering and production knowledge. Fascinating!

Wonderful engineering descriptions of the Ford F-150 by Jordan and Kevin.

Few month review. Offroad, water of maybe like 1/4 up the tire. Nothing crazy, just trails to get to hunting spots. 4WD is truly amazing. SR battery. Only issue is some active air dam fault that I havent got fixed yet. Been twice a day, everyday since hunting season opened. Love it.

🤗 THANKS JORDAN AND KEVIN,AND THE MUNRO TEAM…FOR SHARING AND EXPLAINING EVERYTHING 👍💚💚💚

Sandy and Crew , Thanx Glad your getting recognition for your talents. And $$ too !

Thanks Kevin and Jordan!

I really like the battery support ladder weldment. Sure, many welds, but strong as heck and great protection for the battery while providing meaningful stiffness. Battery isolation is also a win. It's important for people to realize that this isn't a car. Trucks vibrate, bottom out, carry heavy loads, and can be subjected to a great deal of torsion. Building a truck like this allows for long life in rough use. You can climb over curbs and up mountain trails for years and the doors will still line up and it will resist creaks & rattles.

FABULOUSLY clear and yet technically detailed explanations from both presenters. . . Thanks !!!

0:06 Good to see Jordan and Kevin back. I’d point out that Jordan’s consistently professional stance reinforces his already solid presentation. Legs crossed with hands in pocket can connote uncertainty. 😁

Jordan is very articulate, very good at explaining and accurate and able to seamlessly keep the explanation flow ,and understandable Thanks guys great job!

Beautifully done; the folks at Monroe never let us down.

New math: 6 plus 7 equals 14. 🤔♥️

Great talk through Gents. Much appreciated

Taking the cab and body off of this is no doubt easier versus a Rivian. Making access to components for servicing significantly easier. Old school for sure.

As a fascinated non-engineer, decrypting the jargon is a challenge; thank you Google! One week into my Lightning ownership, this systems-oriented pilot is all into understanding how this marvel is designed an put together. Awesome video!

Lead times currently for some of those hoses is months. Now I know who bought them all...

excellent walk through guys!

So basically, this is prototype, Beta version for consumer testing. Total parts bin special, everything outsourced, squeezed into legacy chassis design to fit old production standards & after-market accessories. Great to compare to start-up Rivian, but can’t wait for exoskeleton cybertruck teardown - no frame rails, isolated battery pack & passenger body / cargo tub. This is grandpa truck in comparison, a faster horse (or model T).

I like the discrete module philosophy in terms of serviceability in the long term. Yes, one fully integrated system would be better in every measurable way, except when it comes to replacing a faulty component. That inverter is identical to the inverter used in the HEV f-150 so it has a lot of benefits being its own standalone module

There are so many potential failure points with that many EPDM lines and plastic unions/valves. Those EPDM lines and all the plastic unions and valves will likewise be a parts catalog nightmare!

Thank you all! Great education 🎈

6 + 7 = 14. Got it. 😁

Love watching the break down of this truck. I love mine, its an amazing truck. I haul stuff and it feels like nothing. Range is good for my use (I have the Lariat ER). Drives great, inside is luxury as a truck should be and still be tough. No complaints so far. About 2000 miles and loving mine. The bed, accessories being compatible with F150 trucks gives a ton of options too. From bike racks to simple things like box link, etc. I hope other trucks and future F150 EV stay body on frame. The benefits are more than some realize.

Thank you!

Fabulous in depth comprehensive survey of the underpinnings of the Lightening EV. Looks quite messy and not that well integrated however . Sure will improve as time goes on.

It seems like Ford could use a wider frame and integrate the isolators into the frame, that would keep the geometry they need for existing cabs and beds, and give them more space for battery packaging. But... The hard part is commercial applications where Ford supplies the platform and different companies top it with different rear ends... to keep those Ford has to keep as much existing geometry as they possibly can.

Mice and Rats would have a field day with all those wires and hoses.!!😂🤣🤣😂😉

Looks like spaghetti emulation!

Great job guys !!

If they use the same F150 front control arms and spindle, you could probably run an aftermarket long travel kit with a coil over and bypass shock with weld on shock hoop. Also if fenders are similar to a normal f150 you could also run prerunner style fiberglass fenders. The rear suspension would be custom long travel but at least there is a steel frame to weld shock hoops. Someone is going to build the first EV prerunner and it’s going to be sweet. Out of all the EV trucks this one is probably the easiest to build/ modify for actual off road use.

Love the Content From Munro Live! You Guys are Amazing, Jordan and Kevin

I know that almost all of the Ford engineers who worked on this are watching your videos about the Lightening. And hopefully managers. Heck, they may play them at meetings and disect them. Hopefully they'll listen to your concerns and gen 2 and 3 incorporate your ides. Thanks.

1:18 Love his math skills! 🤯🧐😳

The cybertruck is going to be nuts!!

Except for the maze of hoses and connectors.. This looks nice. imagine all that mess eventually looking like a current model Y under the frunk.. I don't mind having separate electronics so much.. having a separate easily replaceable inverter is nice. But the cooling solution could be masively simplified. NVH on this truck is FANTASTIC.. you don't hear any motor noise. those nice isolators help a lot. I also like that the battery is isolated and pretty easy to pull out. Should allow for repair or upgrade later.

Has anyone noted the ads for ICE vehicles interrupting the video? The Algorithm can’t seen to get that people watching videos on EVs aren’t going to buy ICE vehicles if EV’s are available!

Put a 3 row suv body on this frame and ford will have a top seller.

I remember watching all the Mach-E teardowns, and the interview with Ford about its design issues. Ford did say they learned a lot and you will see improvements in the F-150 Lighting. I'm not exactly seeing anything amazing.

Excellent review. A basic off topic EV question. Of course each supplier has their own proprietary battery, BMS and EV motors. These parts will standardize, commoditize and be multisourced over time. But for now they are very unique (although for little benefit). Is anyone doing parametric analysis of these critical components beyond their structural design? Koenigsegg has that tiny and light high horsepower and torque design. Telsa has (or had) their Halbach efforts. Ford has their solution; GM has Ultium (what 3 now?). BYD and other China manufacturers have blades etc. Battery densities and weights vary. BMS charge and discharge capabilities vary. Is anyone mapping out this critical soul of the EV? Anyone dyno testing? I note that another great KZfaq Channel - Hoovies Garage - came under fire for a recent Lightning post regarding towing. There was the usual KZfaq backlash and a follow clarification video. As I watched that I had to ask myself where a good under the hood analysis was. That is not his discipline or market demographic. Its more of a Munro sort of thing.

Nice job guys

So they are more impressed with the wield than the actual truck 😂

nice converstation between the two. analyzing these will get more interesting with the Cybertruck, still can't wrap my head around that exoskeleton thing.

I can't wait for you to do a tear down on the Toyota Tundra E truck. Oh that's right, it doesn't exist...........yet :) While you wait you could tear down an all electric Toyota Highlander. Oh, right again :)

I'd like to have the tubing contract for Ford. :-)

Love watching the videos..it helps to take the mystery out of the cars/trucks...It's just that I only understand a very small amount of what they are saying...I'm not an engineer.

Looking at the cooling system, I did not realize they would put in two cooling compressors. Hopefully the second compressor will help with charging speed and thermal management when towing up a long grade! Ford is giving a 8 year 70% capacity warranty on the battery. I wonder if they claim a 135 KW battery, then the minimum available power needs to be over 95 KW at the end of 8 years. So if Ford is smart, installing a 145 KW battery, they will have more "Space" to play with before telling a customer that they need to replace their battery at 8 years old, because they can still put in 95+ KW on a full charge. You discuss a long time about the frame width, to make use of the same cab and bed mounts that are common with the 2020 F-150 gas pickup. The frame and battery width really don't matter, for decreased battery capacity in cubic feet to allow so many KW of batteries in the pack. They can just make the battery pack a inch taller and get all the space they need. My thought has always been that the gas F-150 plant will build and paint the cabs and beds for the Lightning so they do not need to duplicate that section of the assembly plant for the trucks built next door. My other guess is they will stop building gas F-150 in Detroit in 2025 model year, and just build gas ones in Kansas City plant. Then try to produce 350,000 a year in Detroit. The E-Transit I think they will keep making them and will have to do a plant expansion around the existing plant. I also think that the gas powered Transit will keep being built for RV's until at least 2033. It is difficult to justify a RV that sits for months to have a very expensive electric drive train. The E-450 / 350 gas Econolines are still being built for the school bus, ambulance, cargo trucks, and RV industries. I think that will keep going on until about 2033, and might change to a electric drivetrain at some point. I am hoping that the F-650 and other trucks will come out in 2028 with a electric version. They might even figure out a way to build gas and electric trucks on the same line? The E-350 / E-450, F-450, F-550, F-600 and F-650 are all built in Ohio along with the RV chassis that is between 14,000 and 24,000 GVWR. I don't know if they have one line that builds one size truck at a time, say the F-450 - F-600 for a couple of weeks than a week of the F-650 and a week of the RV chassis, then back to the F-450 - 600 for a couple more weeks. or if there are separate chassis lines for each size truck.

That battery subframe is going to be a rusty nightmare where I live. It's going to rust around all of those welds. They could at least shoot some LPS 3, cosmoline, or something at it.

Wow, So much great info. Well done team!

Incredibly informative. Jordan and Kevin you really transfer your knowledge well. I noticed signs of rust at 14:20! What do you think about that?

Every time I watch these I learn something. However, every video is about cost, weight, material or manufacturing savings. Never ever about reparability. Being the person that's going to be repairing ever single vehicle you guys review it would be nice if you talked about repairability. As I'm watching these videos that's what I am thinking about. And idevidual components that are not integrated with 10 other components means you can replace a single failed component versus a entire assembly. Please start addressing this for the people that are repairing as engineers of vehicles have been loosing sight of repairabilty for other aspects for years. Vehicles and there compnents should not be throw away items.

All those lines going every which way makes me crazy as a customer knowing there is probably going to be pretty high labor costs involved getting those replaced one day etc.

Yes

The perfect example of Conway's Law at work. The Lightning's design reflects the complex organizational structure that produced it. It's an albatross that legacy automakers that will not easily overcome.

Great job guys you gotta present every video from now onn 👌🏻👌🏻

It's pretty obvious that Ford's experience of building Zillions of body on frame trucks is giving them an advantage for the actual structure.

14 isolated bushings. 6 for the cab and 7 for the bed. 14.

Another great video. Thank you

Hi boys, I hafe a question for you ; is the Lightning fit for aftermarket Fiftwheel accessories ? Besides - super job , congrats out from Austria (not Australia)

Very nice video, really liked it ! How ever I don't like when you want to combine the electronics in to a single module. Reason why, In my country, a car is taxed with 180% at least for ICE cars, so it need to laste for many years as well as mileages. When you have a EDM (EME) module combined with charger or DC/DC converter and it fails, and it will, you have an economic punch in the head. My job is repairing and designing electronics and I have a EDM (EME) on my work bench for a BMW and the price tag is mind-blowing $6500. On the BMW'S EDM (EME) you have charge module, filter, DC/DC, motor controller and some otter stuff. It seams like it is the charge controller that is having the problem and if it was a single module it would have been a fraction of the costs. Wen you looking at the production cost, you never take in to consideration how hard or expensive it will be to repair. However your videos are brilliant, please keep them coming. 👍

tell sandy to do a follow up with elon after you guys have completed your TX model Y report ... would be a great follow up :) :) :) ... you guys rock ...

EDM = Electronic Damce Music. You guys are Kool.

FYI you called the front coil over shock a strut. Just for clarity it is not a strut. It does not pivot or turn at the top mounting point. It is a shock.

This has been a great overview of the general layout and assembly. I will be hoping for a deeper dive into at least the layout of the cooling system, is that small bracket holding a radiator to help heat the interior? Do the active shutters close to maintain a specific battery temp and what range is that temp? All the pumps and compressors are in the front, do those long hoses to the rear require special cooling or heating loads? It seemed many of the cooling lines are not insulated, is that true? If you could do a video of just the cooling system it would be very interesting. Thanks!

cant wait for a cybertruck teardown!

Interesting stuff keep up the great work guys?

I noticed that the two bolts on top of the shock tower are rusted 7:40. Can you explain how these can already be rusted on a new car?

The engine compartment looks lika a spaghetti western....then again this is their first iteration.

17:14 Like a morgue autopsy, when the fresh cadaver's heart starts beating again because the aorta has not been clamped properly...

Finally an upcoming GM truck that doesn't have the rotten waxed frame, that flakes off and looks horrid (quickly) if you live anywhere with salt.

You talk about the difference in the number of body mount points and the compliance of those mounts as if they are unrelated... but they're directly related. The Rivian rigidly connects the frame and entire body so they act as one structure, using many fasteners; like other traditional body-on-frame vehicles, the Lightning does not rigidly connect the cab, using a small number of compliant mounts instead. Like other traditional pickup trucks, the box is rigidly bolted to the frame (at 8 points, although the entire cab only has 6 mounts), and the design assumes that the open-topped cargo box can safely twist as much as the frame does.

What stops them from locating the isolators on top of the frame rails and not on the sides?

One thing I’m noticing is the apparent rust areas on a new chassis, or bolts and shafts it looks. Maybe I’m seeing it wrong but if that indeed is the case they need nip that mess in the bud.

You guys care to cover this recent news from Ford? I don’t recall you guys realizing either that their wiring harness is 1.6 kilometers longer than it needs to be for Electric F-150 and Mach-E. But this is what you do right?? “Ford CEO Jim Farley was rather blunt about the problems that Ford experienced as it rolled out its hot EV models, the Mustang Mach-E and the F-150 Lightning pickup. While both vehicles have a long list of waiting customers, Farley admitted that Ford encountered numerous problems with their production. “We didn’t know that our wiring harness for Mach-E was 1.6 kilometers longer than it needed to be. We didn’t know it’s 70 pounds heavier and that that’s [cost an extra] $300 a battery,” he said on a call with investors Thursday. “We didn’t know that we underinvested in braking technology to save on the battery size.” Farley said these and other cost problems meant that Ford “left about $2 billion of profit on the table.”

I think the Rivian just had soooo many design goals and constraining dimensions. It’s smaller. And I think they as a new company we’re just a little prepense to over-engineer.

Great video, never realized that so much was actually taken from the ice vehicle. Guess this is how most legacy auto will try to make electric vehicles.

Who builds the electric motors for this truck? Is it Magna or Borg Warner?

Uh oh, Jordan, don't forget to like and subscribe.

Great video guys!! I always learn a lot from these. From watching your other tear downs the key take away on the Lightning for me is I see A LOT of wasted materials, A LOT of additional weight and unnecessary components. Ford is still building the Model T. They just don't seem to pivot quickly due to the embedded silo systems.

Question? AT 17:01 instead of fasteners, what about a slide in grooves or tracks?

The Silverado EV has the cab connected to the bed. Just like the Rivian and the 2002-2013 Chevy Avalanche. Unibody on frame. You should go check out a crash Avalanche to see what Chevy did in the past.

Jordan, Jordan! You failed to ask people to like and subscribe! Corey will be.........Disappointed.😄

Interesting that Ford leveraged the ICE body structures. In an interview over a decade ago Musk was asked if he could see his company acquiring one of the Detroit companies. He gave a very thoughtful answer. In Silicon Valley mergers and acquisitions are just a matter of course. They do a lot of them and with that volume comes some very hard learned lessons. Musk's answer elucidated the need for a cultural fit between the two companies and said he saw none that could align with Teslas newer methodologies. He sighted entrenched thinking "that's just how its always been done" as a major hurdle. You hear similar from Sandy. Yes the Lighting was brought to market fairly quickly but is it optimal? Is that necessity a burden to the EV product? Will it ever be optimized or is it to be saddled with that, albeit refined, legacy? In Silicon Valley the term "disruption" is applied to someone who pursues an established market in a way that relegates the installed leader to a follower position. It is exactly this sort of legacy thinking that is often the target. The comment, "Why do they continue to do it that way?" is often answered with "because they have been doing it that way for so long they are blind to any other way". Add to that internal fiefdoms, limited supplier options (often contractual) and lost tribal knowledge and you quickly see how an answer is caste in stone before any new thinking is entertained. Executives unwilling to take risk is also a HUGE impediment to innovation. In Silicon Valley risk is embraced. John Chambers at Cisco Systems once said to his Engineering teams, "If you do not fall down occasionally I don't think you are trying hard enough to win the race."

@1:20 6 cab mounts, plus 7 bed mounts, equals 14 mounts total?

Isn't the battery structure aluminum? Is there a barrier between that and the steel subframe it fastens to? Seems like a lot of salt in the winter would get in that area and cause some corrosion.

Will you take a look at the ioniq 6 when it comes out?

The problem with integration is a small problem with one part means you're changing a large expensive part rather than just the thing that went wrong. Good for the production line, not so much for the consumer.

The Lightning is a modified F-150 platform where GM Silverado EV BT1 is a EV from ground up next year. Wait for Ford 2025 redesign. The Ford F-150 Lightning is already being promised a redesign for the 2025 model year. Reuters mentioned this when discussing Ford’s production plans for the Lightning.

Is there a way to connect a snow plow to this truck? Is the Frunk Bucket and cooling radiator in the way? Is the 12 volt System capable of running a standard Hydraulic lift and snow plow controls? Do Snow plow manufacturers have to be supplied with a HV Battery Power Outlet connection and redesign their hydraulic system to run on HV battery power?

I’d like to see a discussion about maintaining this mass of pipes, that must not leak, when the truck is 6 to 8+ years old?

Agree, this vehicle was rushed to get it on market. I wouldn’t waste my money investing in Ford or GM.