With about 3,500 miles on the Lithium batteries, that's about 80 charge cycles, everything is working well. We make the climb up the long hill with ease now, even with groceries and a passenger. Driving the car is more enjoyable now so I find that I drive her more often. I think I'll even put in a nice CD player.
I occasionally need to top-off a few of the Lithium cells individually because my charger doesn't step down it's output until it reaches about 176 volts. The BMS shuts off the charger when any cell reaches 3.79 volts, which often happens before the charger reaches that step down point. With such high output the balancer can't shunt off enough to keep voltages under the limit, so it shuts off the charger. I should just re-program the charger to step down from the high output at around 168 volts, then the balancing system would work automatically.
When the BMS gets up to where it is balancing (shunting?) about 35 to 40 cells and it's over about 85 degrees outside the BMS unit gets too warm and shuts off. This is with the trunk open, parked in the shade, with good airflow. I can still charge the pack by turning off the balancing function. This over-temp shut off didn't happen when it was 60 or 70 degrees outside.
If I converted another Force I would seriously consider using 50 of the 100Ah cells. Mine settle to about 3.4 or 3.5 volts soon after the charging stops so the pack voltage would be within the controller limits. I'd also consider using individual chargers set-up on a timer ($500 ~ 600). That way all the cells would always get fully charged without using a balancing system ($900) and a high voltage charger ($1,000).