Safety Recall 22S41 - 2021-2022 Mach E - HVBJB Recall [high voltage battery main contactors may overheat]

[billy_at]

If 286 warranty claims have been made out of approximately 50,000 vehicles, that’s a failure rate of 0.5%.

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[mikeinet]

Solid write up…

ford is really putting all their eggs in the basket that OTA issues are fully resolved now! I sure hope so!!!

 

[machefan]

A few things come to my mind here.

- Thanks for posting conclusive information.
- Glad it's software and not hardware.
- Other threads were popcorn time and entertaining.
- Hopefully someone sees when the new software is avail on FRDS.
- Tread lightly on the pedal until the software is loaded on ones MME. (Guessing here)
- Way to much talk about Job 1 - Job whatever being better or worse, so far that has not proven to be true.
- Software - Software - Software is the new location location location.
- Still love my MME FE JOB 1 2020 build, it's been a joy.

Happy hump day all!

 

[rapture89]

You misread. Ford, and others, want the tax credit to extend beyond 200k vehicles. This would benefit some of the competitors for whom the tax credit is no longer eligible.

Thank you for correcting me that is good news, thanks!!!

 

[hybrid2bev]

The recall has now been posted to the NHTSA website with lots of details.

They confirm it's only a software update:



And every listed component (all 50 of them) in the attached PDF is software - no physical parts mentioned.

The document also confirms updates will be available in July (not just the vague "Q3" we heard yesterday).

It also describes what the software will do:



It sounds to me like this will reduce power only when a dangerous situation with the contactors has been detected - I imagine when you've got the combination of DCFC and flooring the pedal that Ford mentioned yesterday.

On the bottom of page 10, it says the problem was corrected in production simply by introducing new software on May 25, 2022. The speculation about different hardware being used in post-May 25 builds seems to have been unfounded:

Other interesting historical details:
* VOQ = Vehicle Owner Questionnaire

So 286 failures / 49,000 recalled vehicles in North America = about a 0.58% failure rate?

 

[NewGuy]

Here’s hoping the software update will be available to dealers prior to this to get those of us on delivery hold taken care of lol. Mine is at my dealer but I can’t get it until this is fixed. Fingers crossed!

I’m in the same boat. It’s encouraging that this software update must already be done if it’s in cars made in late May.

Maybe we’ll be able to get our cars before July after all…

 

[New Edge]

I’m in the same boat. It’s encouraging that this software update must already be done if it’s in cars made in late May.

Maybe we’ll be able to get our cars before July after all…

Maybe. My delivery was changed from a 6/10-16 window to 6/27-7/3 as of two days ago and the email came to me last night. We’ll see. My dealer rep didn’t answer me yesterday regarding my query on my cars status so I wonder if he even had any clue yet about the recall

 

[mmap]

On the bottom of page 10, it says the problem was corrected in production simply by introducing new software on May 25, 2022. The speculation about different hardware being used in post-May 25 builds seems to have been unfounded:

This is a regulatory/legal filing. It won't contain "extra" or "unnecessary" information. The underlying cause is explained in filing as "...high voltage battery main contactor is not robust to the heat generated...". That obviously can be fixed with a "robust" part.

The recall isn't going to fix them that way, because it is cheaper to fix it with software.

My unsupported internet speculation is that if the new software monitoring "contactor resistance to identify an overheated contactor" finds that condition, that it will give the owner a wrench and a "service vehicle soon" warning. And then those people will get new HVBJBs (under warranty).

 

[KevinS]

I’m in the same boat. It’s encouraging that this software update must already be done if it’s in cars made in late May.

That's the thing I can't figure out. I suppose they're doing more testing of the software fix for edge cases of cars already on the road.

And then one must wonder if the HVBJB could be partially affected by prior incidents that isn't a complete failure but isn't quite right.

I'll just keep driving with common sense and keep checking FDRS for an update. If I'm even going to fret, that's the most I can do that I can do.

 

[KevinS]

Ironically, despite the headline of the first post in this thread, the NHTSA recall specifically says you should "call your dealer"! ?

I'll give you three guesses about which one was publicly available before the other one...

 

[Benny’66]

This software “work around” is a Band-Aid fix. As a GTPE owner who is already dealing with the 5 second power limiter on a performance vehicle, now we implement more limits? Someone didn’t do their job which means we go back to the DFMEA and find a part that won’t melt down!

 

[billy_at]

And then one must wonder if the HVBJB could be partially affected by prior incidents that isn't a complete failure but isn't quite right.

This is what I really want to know. Have past incidents of DCFC and flooring it without the updated software weakened or damaged the HVBJB in some way, making it more likely to fail in the future?

 

[billy_at]

It sounds like it only limits the power in a relatively rare and temporary situation caused by specific factors (something to do with DCFC and flooring it) which creates a safety issue.

That sounds totally fine and reasonable to me?

Very few MME’s have ever experienced the problem. If mine does, I’d prefer the car to make temporary power adjustments rather than blowing out the contactors in the name of “MOAR POWER!” It really does not sound like this is an everyday problem.

 

[NewGuy]

A few things come to my mind here.

- Thanks for posting conclusive information.
- Glad it's software and not hardware.
- Other threads were popcorn time and entertaining.
- Hopefully someone sees when the new software is avail on FRDS.
- Tread lightly on the pedal until the software is loaded on ones MME. (Guessing here)
- Way to much talk about Job 1 - Job whatever being better or worse, so far that has not proven to be true.
- Software - Software - Software is the new location location location.
- Still love my MME FE JOB 1 2020 build, it's been a joy.

Happy hump day all!

Folks have reported that updates to affected modules were posted to FDRS on May 24. Not sure if it’s THEE update though.

https://www.macheforum.com/site/thr...ain-contactors-may-overheat.18681/post-441720

 

[FLmac]

Is it confirmed now that it will be a software update at least for now? And as a result our deliveries won't be delayed by that long? Or is it all still somewhat up in the air?

This would be the best news (for me at least). I am currently borrowing a car from family, and my delivery was 2 weeks away

IMO, which isn’t based off anything other than reading 47 pages of this, I think it will start with a software update that may limit some performance and DCFC charging. For cars like mine this will probably work, premium AWD SR. I hope Ford will do the right hint and if cars need a part those cars will get a new part. I can understand trying to keep as few cars bricked while they get them in for the recall and the new part. I’m sure they have a whole set of lawyers running cost analysis of this recall, limiting performance, class action lawsuits, and the PR nightmare and cost. All of this was voluntary by Ford and so far I want to believe they are trying to do the right thing even if it’s for the wrong reasons.

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