Mach E GTPE *Bricked* @ BMW i4 M50 Drive Event !?!

Capt_Everything

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**Update**

4/15/22 afternoon

Scooped up my GT and all appears to be good!

Big thanks to several forum members here that helped scoot this along!

The case manager at Ford corporate was helpful and maintained good contact.

It wasn't a bad turn around for the work that needed to be performed!

Hopefully the new junction box performs better than the old one!

4/15/22 noon

Called the service department at noon to see if paperwork submitted for LVB replacement. To my surprise I was told the battery tester they used on the LVB was faulty and that the battery did charge overnight as it should. Sounds like I'll be able to pick it up later today...

4/14/22

Work completed only to find LVB will not charge.

No ETA on LVB!

This is an amazing oversight by Ford. To introduce a "one of a kind" lightweight AGM battery as the only LVB part approved. What a linchpin!

Brighter minds then mine at Ford should be working on spooling up an additional LVB supplier ASAP to augment need.

4/13/22

Well this is sad.

It's back together and is driveable but it won't charge properly. Currently the problem is undiagnosed without further info on how they will proceed. Time for another rental car.

Two weeks now without the Mach E.

4/12/22
Dropped by service center late morning and battery was already installed. Briefly spoke with tech who seemed confident and has been getting guidance through an online video conference. Was told that they have to reprogram all modules (including both FOBs) and it would take 7 hours and most likely be done overnight. It's odd to me how replacing contractors/relays (HVBJB) would require that. I'd really like to understand better why that is needed. Maybe I'll get some new code but I kinda doubt it because I updated all modules only about a month ago or so. Case manager from Ford corporate also checked in to with an update that it will be done probably Friday. Tech seemed to think tomorrow when I spoke last but maybe another issue popped up. We'll see tomorrow I guess.

4/11/22
The HVBJB part has been recieved by the service department and I stopped by to say hello to the tech who was prepping the battery for removal. He was draining the coolant lines from the battery and it looked like some high voltage cables were already disconnected. I got a few pictures of the new HVBJB I'll post.
The field service team had met with the tech and I believe they'll return tomorrow for the case cracking. As those of you reading up on this it sounds like it's they're down to simply an HVBJB replacement rather than that combined with the harness and the BECM.

4/7/22
Customer experience specialist- called to update me. Parts in transit, next Tuesday will call back to update me. Vehicle might return to service by end of Tuesday.

It was nice to be updated.

4/6/22
Refer to Post 66 (couldn't edit op for some reason)

4/5/22 night

Couldn't sleep last night until late so I went through the workshop manual. I totally forgot I had it. It doesn't take a genius to go through the logic tree and see that the BECM and HVBJB need replacement. The manual seems pretty good. By the time you get to be a mid career pilot, you get used to reading some pretty lengthy dry manuals.

Below is the one manual page that directs replacement of BECM & HVBJB and a few pages from the Falcon Fault dispatch guide, it operates in somewhat a similar manner which is cool. Thing I like about the Falcon guide is its all hyper linked so you get to answers quickly.


4/5/22 evening

I got contacted by the Ford corporate case manager a few hours later saying they spoke with the service representative and they are now saying they ordered parts to repair the system...
I'm thinking the HVB battery request may have triggered interest from Fords EV department to review the codes and reassess what the remedy should be...

The case manager said that it may be done by end of week.


4/5/22 morning
After spending yesterday trying to investigate which of the local Fords had the better EV department I discovered the one I chose was scantily equipped. I discovered how it's impossible to be part of the solution and even an intelligent customer is to wait and shut up.

A call today just came through that they ordered an HVB with no ETA. That's it, no description why by the service rep and no willingness to allow a conversation with the sole EV tech.

Confidence in a timely repair without further intervention is zero.

I remember a significant argument for Ford and against Tesla was, "well Ford has service centers all over, Tesla doesn't." Seemed rational at the time...


------------------------------------------------------------------------
March 31 2022

Well, today i got to test drive the i4 M50 on a small autox. Nice event, lots of cars, decent seat time.

In fact I'm still here, Stuck here.

Walked back to my GTPE, held the brake, hit the start and the dreaded "STOP SAFELY" red box popped up along with the flashing green start light.

What poop! All the BMW tests drivers getting to see this Ford being a Found On Roadside Dead! No a good look lol.

Hood popped, panels ripped off, attempting a jump of the LVB in case that was the issue and eventually a ground disconnect to attempt a computer test.

All to no avail!

Ford roadside app had a tow truck driver call quickly only to say he wasn't allowed in the state parking lot and road. Called the roadside number and quickly got ran in circles stating the tow truck was contacted, good bye. Of course that one isn't coming so I had to find out who is authorized to tow these roads.

+5000 miles, built Sept 2021, GTPE... was fun up until now.

Ford Mustang Mach-E Mach E GTPE *Bricked* @ BMW i4 M50 Drive Event !?! 20220331_161704


Ford Mustang Mach-E Mach E GTPE *Bricked* @ BMW i4 M50 Drive Event !?! Screenshot_20220406-002317_Photo Editor


Ford Mustang Mach-E Mach E GTPE *Bricked* @ BMW i4 M50 Drive Event !?! 20220406_002810


Ford Mustang Mach-E Mach E GTPE *Bricked* @ BMW i4 M50 Drive Event !?! 20220406_002825


Ford Mustang Mach-E Mach E GTPE *Bricked* @ BMW i4 M50 Drive Event !?! 20220406_002933
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Capt_Everything

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Tired to pull some codes.

Car Scanner ELM OBD2
DTC report
Selected brand: Ford
VIN: 3FMTK4SXXMME02289

============1==============
P0563
Raw code: 0563
ECU: 7EC
Status: Confirmed
OBDII: System voltage - high
Ford: System Voltage High

============2==============
P0AA1
Raw code: 0AA1
ECU: 7EC
Status: Pending
OBDII: Hybrid battery positive contactor - circuit stuck closed

============3==============
P0563(00)
Raw code: 056300
ECU: 7EC
Status: Test failed (current drive cycle), Pending, Confirmed, Test failed since last DTC clear, Warning indicator requested
OBDII: System voltage - high
Ford: System Voltage High

============4==============
P1A10(00)
Raw code: 1A1000
ECU: 7EE
Status: Test failed, Test failed (current drive cycle), Pending, Confirmed, Test failed since last DTC clear, Warning indicator requested
Ford: HYBRID POWERTRAIN CONTROL MODULE - BATTERY DISABLED

============5==============
U0416(00)
Raw code: C41600
ECU: Engine control unit[Archive (inactive)]
Status: Test failed since last DTC clear
OBDII: Invalid data received - vehicle dynamics control module

============6==============
P0CF7(66)
Raw code: 0CF766
ECU: 7EA[Archive (inactive)]
Status: Test failed since last DTC clear, Test not completed during this operation cycle

============7==============
P0AA1(00)
Raw code: 0AA100
ECU: 7EC
Status: Test failed, Test failed (current drive cycle), Pending, Test failed since last DTC clear
OBDII: Hybrid battery positive contactor - circuit stuck closed
 

JohnC

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So sorry this has happened to you, Capt_Everything.

It's getting to the point where I'm afraid to drive my car for fear of it breaking down.

What the hell is going on with these failures and what is Ford doing about it?
 

SnBGC

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Looks like the HVB positive contactor didn't release when parked and shut down. :(
 
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Capt_Everything

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Anyone that wants to see an involuntary static of a Mach E GTPE and actually test drive one of the 8 BMW i4 M50 EV's the event is still going on at Tobay Beach on Long Island New York. Was a fun little course!

I'll be here until the tow truck arrives.
 


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Where is that located so I can smack it with something blunt?
On top of the battery pack. The worst most inaccessible possible place to locate it. Not one of Ford's better ideas unfortunately...

The GTPE likely has the highest amount of current that runs through that component than any other model. The HV connection points are a concern item with EVs (along with several other items of course)

I hope your issue is a simple and quick fix.
 

noway

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The point is that this contactor is supposed to cut the voltage as close to the cells as possible, it is the feature that is making the car safe in an accident.

But it still too bad that small things like this renders the car completely useless. It should in some way had a failsafe where it could try again and possibly show a warning if it has to do so. The fault code probably needs to be cleared before the car will work agan, even if the problem is resolved (which it probably does by itself).

There is a small disconnect "switch" located right next to the HVB (small red thing (not the wire loop for the charge port). Has to remove the covers to find it, looks like a fuse mount on wires), it can be removed to "manually" disconnect the low voltage supply to those contactors. If there is some fault making them stay open it could be worth a try to just remove that in case there is a small leakage voltage keeping the contactors on.

They should have had dual contactors in series.. in case one got stuck
 

chrisGT

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Sorry to hear about your troubles. Unfortunately we hear about a new bricked MME every day and no recall from Ford yet.

Btw, did you DC fast charge recently? I have a hypothesis that connects DC fast charging to the problem. Either DC charging fries some modules or pulling out the cable without properly stopping charging results in some electrical arc. Again just hypothesis.
 

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Well, today i got to test drive the i4 M50 on a small autox. Nice event, lots of cars, decent seat time.

In fact I'm still here, Stuck here.

Walked back to my GTPE, held the brake, hit the start and the dreaded "STOP SAFELY" red box popped up along with the flashing green start light.

What poop! All the BMW tests drivers getting to see this Ford being a Found On Roadside Dead! No a good look lol.

Hood popped, panels ripped off, attempting a jump of the LVB in case that was the issue and eventually a ground disconnect to attempt a computer test.

All to no avail!

Ford roadside app had a tow truck driver call quickly only to say he wasn't allowed in the state parking lot and road. Called the roadside number and quickly got ran in circles stating the tow truck was contacted, good bye. Of course that one isn't coming so I had to find out who is authorized to tow these roads.

+5000 miles, built Sept 2021, GTPE... was fun up until now.

20220331_161704.jpg
That photo is a great advertisement for the BMW. " Tired of a bricked Ford electric, come over to BMW"!
 

Rabidsquirrel22

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Mach-Lee

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Sorry to hear about your troubles. Unfortunately we hear about a new bricked MME every day and no recall from Ford yet.

Btw, did you DC fast charge recently? I have a hypothesis that connects DC fast charging to the problem. Either DC charging fries some modules or pulling out the cable without properly stopping charging results in some electrical arc. Again just hypothesis.
Yes, sounds like yet another failed HVBJB. They will have to drop the pack to replace it.

He has a persistent P1A3C code in OBCC, TSB 22-2057 calls for an update to the OBCC for this. Also curious if he's had issues with DC charging. Sept 17 2021 build date, does not look like he's had any software updates yet.
 

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What a bummer! Of all places to have a failure!
 
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Sorry to hear about your troubles. Unfortunately we hear about a new bricked MME every day and no recall from Ford yet.

Btw, did you DC fast charge recently? I have a hypothesis that connects DC fast charging to the problem. Either DC charging fries some modules or pulling out the cable without properly stopping charging results in some electrical arc. Again just hypothesis.
DC charge only 1 time a month or less, it's been 2 level 2 charges at home since I last DC charged at an EA station from 58~75%
 
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Capt_Everything

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The point is that this contactor is supposed to cut the voltage as close to the cells as possible, it is the feature that is making the car safe in an accident.

But it still too bad that small things like this renders the car completely useless. It should in some way had a failsafe where it could try again and possibly show a warning if it has to do so. The fault code probably needs to be cleared before the car will work agan, even if the problem is resolved (which it probably does by itself).

There is a small disconnect "switch" located right next to the HVB (small red thing (not the wire loop for the charge port). Has to remove the covers to find it, looks like a fuse mount on wires), it can be removed to "manually" disconnect the low voltage supply to those contactors. If there is some fault making them stay open it could be worth a try to just remove that in case there is a small leakage voltage keeping the contactors on.

They should have had dual contactors in series.. in case one got stuck
I like the idea of a cut off as close as possible. Redundancy would be nice though.

When I go drop off the second key tomorrow at the service center maybe it works be worth trying the manual disconnect, although at this point it might not be worth the stress.
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