My "Stop Safely Now" Saga

[scoopman]

I think Ford owes us transparency and a redesigned part. It’s not right that this battery pack clearly has a design flaw that is not being properly addressed.

I don’t feel confident taking my Mach-E on my upcoming family road trip because I cannot trust it with this unacknowledged design defect.

It might be a reasonably low probability, but if it happens it is catastrophic and I want to minimize the potential of such drama for my family when we’re not local.

I’ll probably start considering switching to something else if I don’t see a new part in my car or a plan from Ford soon.

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[dtbaker61]

the confounding thing is that *most* of us have not had any problems, but a *very few* have had repeat problems with the same car.

Makes me wonder if the root cause is a mechanical design flaw, a very specific assembly/install error, software sequencing error opening/closing contacts, or some specific pattern of use/charging that cause repeat failures in the same vehicle while most cars never exhibit the failure.

I can't help but wonder if the numbers and chances of failure go up with the frequency of DCFC use, because it seems that *most* owners primary charge at home, or the occasional L2 public charger.

 

[heisnuts]

Only you can decide when it might be time to call it quits. But you might want to read the thread
https://www.macheforum.com/site/threads/i-just-joined-the-stop-safely-now-club-too.17454/ before you decide.
This member mentions that Ford may be testing a resolution/fix for the HVBJB in his repair. Too soon to tell, but I take this as hopeful.

I am the one in the post you quote and I must say at least in my case Ford really seems to be taking this seriously and coming up with a solution. In my case Ford engineering contacted my dealer even before they had the car in the shop (which I am sure surprised even the dealer), they sent out a field engineer to the dealer to perform this new procedure coming out in the TSB, and the dealer had the car back to me in 10 days. I have a feeling if the OP wasn't running into the problems with the battery case that keeps coming in damaged he too would have had his car back a lot sooner. I have a feeling any future failures should have a lot faster turn around once the TSB comes out. I really feel sorry for the OP here and the others who have had the frustration of this failure.

Time will tell on the repair, but so far I have taken it out in the country like I normally do for over two hours at a time and have not had any problems. Like I said in my original post this forum has helped out tremendously with all of the information that has been posted from so many members and Ford who's rep reached out immediately once I posted of my own failure and got the ball rolling for repairs.

 

[Mach-Lee]

Today's update: Tech informed me that Parts COPIS is telling them they're sending ANOTHER cover to be inspected for foam prior to shipment. For those keeping track, this is the FOURTH battery cover (including the original). And tomorrow marks 30 days out of service.

The foam pads on top are a seperate part. Tell your dealer to order part # LJ9Z-58044E84-B (FOAM PAD - ENERGY ABSORBING). The technician needs to install them in the outlined areas, that's why they are marked on the top case. They will also need a new vent patch, which is part # LJ9Z-10A815-A (GASKET - H/V BATTERY VENT COVER).

Not sure why there's so much confusion, the workshop manual says these items need to be installed on the new cover and it only takes a couple minutes to look up the part numbers.

 

[Regularmache]

I have to be honest, built Dec 2020 and we never have DC Fast Charged and over 17 months no issues. ( Front driver's door has too tight if clearance and have a rub spot.).
Cases like mine though any automaker can look good, you know what type of company they really are when issues arise and how there handled.

 

[Tedro7]

I am now the newest member of the "Stop Safely Now" club. The car has been sitting in the service lot at the dealership going on the 9th day now. It hasn't even made it inside the service area yet. The service agent left a VM on May 19th saying they were still trying to figure out how to get the car inside to a service bay so they can find out what is wrong with it.

 

[Regularmache]

Another GT, hmm. Were you Fast Charging often by chance?

 

[Tedro7]

Another GT, hmm. Were you Fast Charging often by chance?

No, sir.

 

[scoopman]

I am now the newest member of the "Stop Safely Now" club. The car has been sitting in the service lot at the dealership going on the 9th day now. It hasn't even made it inside the service area yet. The service agent left a VM on May 19th saying they were still trying to figure out how to get the car inside to a service bay so they can find out what is wrong with it.

That sounds horrible. Sorry this happened to you. You might want to ask @Ford Motor Company to open a case for you and poke your dealer to get off their butts.

While you wait, could you please fill out the complaint form on NHTSAs web site? I think it’s important we keep pressure on Ford to address this serious safety issue for all owners, not just when your car fails as it may be the case with a TSB.

Form here:https://www.nhtsa.gov/report-a-safety-problem#index

 

[scoopman]

I am the one in the post you quote and I must say at least in my case Ford really seems to be taking this seriously and coming up with a solution. In my case Ford engineering contacted my dealer even before they had the car in the shop (which I am sure surprised even the dealer), they sent out a field engineer to the dealer to perform this new procedure coming out in the TSB, and the dealer had the car back to me in 10 days. I have a feeling if the OP wasn't running into the problems with the battery case that keeps coming in damaged he too would have had his car back a lot sooner. I have a feeling any future failures should have a lot faster turn around once the TSB comes out. I really feel sorry for the OP here and the others who have had the frustration of this failure.

Time will tell on the repair, but so far I have taken it out in the country like I normally do for over two hours at a time and have not had any problems. Like I said in my original post this forum has helped out tremendously with all of the information that has been posted from so many members and Ford who's rep reached out immediately once I posted of my own failure and got the ball rolling for repairs.

That’s great they tried out the new solution on your car, whatever it is. My car didn’t get that, just another same defective part which could fail once again.

What is critical is what criteria Ford will use to determine whether to apply the solution to a car. Is there some test to run to determine if a HVBJB will fail in the future? Will the TSB just be a different repair procedure after a HVBJB fails?

This needs to be a recall not a TSB.

I should not have to wait and see if the electronics fail again, such as when I’m on a road trip 500 miles from home with my 4 and 7 year olds in the car, and then just hope we are safe while my car is towed, for Ford to fix the defect properly the second time through this TSB.

This isn’t like having a leaky windshield.

This is a safety defect that needs to be addressed by Ford before your car catastrophically fails, not afterwards.

 

[newmme]

This needs to be a recall not a TSB.

I should not have to wait and see if the electronics fail again, such as when I’m on a road trip 500 miles from home with my 4 and 7 year olds in the car, and then just hope we are safe while my car is towed, for Ford to fix the defect properly the second time through this TSB.

This isn’t like having a leaky windshield.

This is a safety defect that needs to be addressed by Ford before your car catastrophically fails, not afterwards.

This has been happening for 1 year, not a good look for Ford. Crazy!

Stop Safely Now. Car left me stranded!

 

[Electric Goat]

This thread is really emphasizing that this issue is a complete sh*t show.

I know that there are some Ford engineers and management that read this forum.... Can any of you please say something of substance? Create a burner account and say something... jeezus.

 

[Mawby]

I always find it surprising when an entire company gets banished for issues with a first year car run. If it were a rivian or a fisker I would be alarmed but knowing they are new mfg companies I would not and should not be upset. Repeat occurrences for defects implies design flaw. Like the decision to make the 12v battery control all ui and when it fails it cannot Leverage some limited get to a dealer soon mode with hvb but instead a hard stop.

 

[heisnuts]

That’s great they tried out the new solution on your car, whatever it is. My car didn’t get that, just another same defective part which could fail once again.

What is critical is what criteria Ford will use to determine whether to apply the solution to a car. Is there some test to run to determine if a HVBJB will fail in the future? Will the TSB just be a different repair procedure after a HVBJB fails?

This needs to be a recall not a TSB.

I should not have to wait and see if the electronics fail again, such as when I’m on a road trip 500 miles from home with my 4 and 7 year olds in the car, and then just hope we are safe while my car is towed, for Ford to fix the defect properly the second time through this TSB.

This isn’t like having a leaky windshield.

This is a safety defect that needs to be addressed by Ford before your car catastrophically fails, not afterwards.

I agree with you and I have a feeling that a lot of this fix is software related that controls how things operate in the background for the high voltage system and charging. I also have a feeling this will either be a recall for the update that requires a dealer visit or an OTA update… Hopefully it will be an OTA.

 

[scoopman]

I'm ready to go if its in FDRS.....

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