😭😭😭 POST BATTERY CONTACTOR RECALL -- FIRST JUNCTION BOX FAILURE 😭😭😭😭

[DevSecOps]

The NHTSA notice says "Description of safety risk: An overheated contactor that opens while driving can result in a loss of motive power, which can increase the risk of an accident. " So it's not just when you stop, although that seems to be the much more common scenario here on the forums.

The only way I know a contactor can "overheat and fail open" is the coil melting (but not the spring). That usually has more to do with supply voltage than with the actual power across the contactor, but I dunno maybe if the contacts get hot enough...

Yeah ... not sure why that is in there or if I believe 50% of the NHTSA recall notice anyway. There's a few things in the notice that don't make sense. When the car is turned on the HVBJB contactor to the HVB is engaged and "closed". While it can weld open, the instances I've seen of that happening are when it's turned off, not in motion.

I don't think we've seen a single confirmed HVBJB failure on this forum where someone was driving along and it just flipped open and welded. Other SSN errors I think we've seen where there's electrical shorts. Maybe they do happen but if they do, It's likely to be a 0.01% chance ...

Sponsored

 

[Mach-Lee]

The service advisor told me that the tech started to diagnose my car late yesterday and he was told "the recall had not been performed, some of the modules weren't configured" but that Ford's field engineer told the dealer to stop what they were doing, order the part, and he would oversee the repair next week. Service advisor couldn't tell me whether my car started up again or not, but it sounds like it probably did or they woulda mentioned something about the 5000lb bright yellow stuck car I dropped off.

I think the dealer was freaked out that my car was updated without the recall computer system noting that my car had the recall performed. I know it is BS that the modules weren't configured, everything showed completely up to date and configured when I flashed in FDRS myself.

I just think this dealer really isn't used to a customer knowing more than them, and having Ford's field engineer calling them proactively. I think it freaked them out.

Yeah seriously. If you cleared all codes after updates and there weren’t any config codes that reappeared you’re good. Too many service advisors just spit out bullshit by default.

I'd love to see carscanner data for doing 75/80mph on a level grade just as a baseline for current required to maintain the speed. I need to go for a drive...

I’d like to see a data log from another brave soul who wants to drive up the grapevine at 80 mph on cruise. Amps, pack, and contactor voltages. That’s looking like it may be the new HVBJB test course…

 

[mikeinet]

I know, he sold his character for multi-hundred millions. I had 5 hours of Blippi mixes on Apple Music yesterday.

I'm sorry.... more for this than for you car... ( I know brutal that can be!!!! LOL)

 

[VegStang]

Wow, just wow. Thanks for commiserating on my own HVBJB failure, and thanks for getting the photos on your new one. While i'm glad that the new sw allowed you to hobble to the hotel and then to the dealer having this happen on a road trip down the 5 sucks.

I've also been trying to keep the service advisor on my side as I wait for my car- ? they get your new one installed and finished next week. Hopefully the taco stand in Alham-brah will do as well as Sunnyvale, and the new part will get us all out of the ticking time bomb life.

I just called the ? restaurant and they ordered an extra beefy robust mucho grande burrito especialle late yesterday, delivery hopefully by Tuesday (as Monday is Independence Day holiday).

The service advisor told me that the tech started to diagnose my car late yesterday and he was told "the recall had not been performed, some of the modules weren't configured" but that Ford's field engineer told the dealer to stop what they were doing, order the part, and he would oversee the repair next week. Service advisor couldn't tell me whether my car started up again or not, but it sounds like it probably did or they woulda mentioned something about the 5000lb bright yellow stuck car I dropped off.

I think the dealer was freaked out that my car was updated without the recall computer system noting that my car had the recall performed. I know it is BS that the modules weren't configured, everything showed completely up to date and configured when I flashed in FDRS myself.

I just think this dealer really isn't used to a customer knowing more than them, and having Ford's field engineer calling them proactively. I think it freaked them out.

I didn't argue at all with the service advisor or even try and contradict him, I need to keep him on my side. He agreed to take a photo of the new part when it comes in and send it to me, for everyone interested....

 

[DevSecOps]

I’d like to see a data log from another brave soul who wants to drive up the grapevine at 80 mph on cruise. Amps, pack, and contactor voltages. That’s looking like it may be the new HVBJB test course…

I've done I80 and I50 from Sacramento to Tahoe many times in the MME. It's about 3-4k more in elevation than the grapevine. We have a lot of roads like that in California where we go from 0 feet to 4-8k in 50 miles or less. My dad lives in Lake Tahoe so it's a routine trip I make. 80 miles uphill and I burn through 80% of my battery doing it.

Additionally, every Monday, for work, I drive over Pacheco Pass and Altamont Pass, both lower in elevation, but nonetheless mountain passes.

Michigan must not have any mountains ?‍

 

[SuperRob]

Yeah that looks good until you think about where you would take that to get it fixed. I had literally 20 Ford dealers in the LA area to choose from, and a dealer with all the right tools and support was 10 minutes away from this hotel we're at.

Also, Fisker designed the car, but the engineering is being done completely by Magna on an unproven "white label" EV platform they have.

Magna's built a lot of EV parts for a lot of companies ... including the rear motor on the Mach-E. I'm not that concerned about it being a Magna platform. I am more concerned about them not having an "experience center" up here in the Seattle area, though. That's part of why I went Ford in the first place.

But I'm still waiting on my car and not confident it'll be without it's problems. I had to convince my wife to go EV in the first place, not looking forward to the "I told you so," I'll get if it has issues ... or worse if she's driving when the issues happen!

 

[scoopman]

I'd love to see carscanner data for doing 75/80mph on a level grade just as a baseline for current required to maintain the speed. I need to go for a drive...

I wanted to log car scanner data but my iPhone 13 Pro freaked out trying to run car scanner and wireless carplay at the same time. I'm sure it's multiplexing the antenna between the wifi and BT radios and could not deal with that much real time data at the same time.

 

[Addos]

Cars that have had repeated failures of the part really begs the question of whether the part or software are really the issue, or just a symptom of a bigger problem. Starting to think the software update and part replacement are just attempts to mask a more serious problem.

 

[HuntingPudel]

dealer is covering $40 per day of rental coverage but I will be making ford corporate cover the rest I hope.

I hope you can get something more out of them. I was unable to get them to cover the taxi ride after their tech stranded me. ??

 

[newmme]

We will be impacted, but hey we are the ones that bought this product.

I still remember the speech by the Ford VP, that this product will not have all the problems that Telsa has, such as the roof coming off, batteries issues, etc

Funny, I just ran across this today....did not age too well

 

[Malacandra]

I wanted to log car scanner data but my iPhone 13 Pro freaked out trying to run car scanner and wireless carplay at the same time. I'm sure it's multiplexing the antenna between the wifi and BT radios and could not deal with that much real time data at the same time.

Geez, doesn't Apple appreciate that we're paying a premium to use these things as tricorders?

 

[EVTRAVEL]

July 1 update -- see below for a little more analysis of my DCFC session and messages in FordPass with the new software.

----

I’m keeping this somewhat brief because I have been up since 5am this morning and had a great morning drive to LA turn into the first ever contactor failure with the new recall software (according to Ford). So that took only two days for my junction box to fry itself after the software protection.

My car has the recall software fix and was completely every-module updated in FDRS as of yesterday June 29th. I drove it on a road trip with my family from the Bay Area to LA, this is a little over 5 1/2 hours plus two 20-30-ish minute DCFC stops. There's some terrain as you pass over the Angeles National Forest on I-5 into LA area. I was driving keeping up with traffic generally 75-80mph. Definitely not driving like a maniac and I was in whisper mode.

My car made it almost out of the mountains before LA, about 10-15 minutes after the second DCFC (which was from SOC 55-80% because I wanted the buffer before hitting the mountains) before it failed with a new DTC for contactors. We were almost out of the mountains on the descent when it failed (just before Six Flags Magic Mountain -- for those familiar with the drive).

See photos below with your new, exciting, slightly less-catestrophic failure experience to look forward to -- with some tips. We were able to drive the car on local roads (Google Maps “avoid highways” toggle FTW!) for an additional 1hr 37min to cover the 44mi to our hotel. From there I drove the car (after unloading my family and checking in) to the nearest Ford dealership all without turning the car off (see below for tips).

So Mach N Cheese is tucked in at the Alhambra Ford dealership for probably the next week, where very nice people from Ford are hopefully expediting the revised HVBJB to be installed starting Tuesday if all goes well. (Yes this dealer sorta looks like a taco stand -- without the tacos).

I have a full video on the fun (until it was not) roadtrip that I’ll be editing over the coming days, but some quick tips on what happens with this genius new software if it thinks your contactors are failing.

You get this message WHILE DRIVING:

No other information. But your power is then limited A LOT. Check out this power jail!

DTC codes I had:

Note you can clear these codes, and the car will pretend everything is great .... but really it is not. Don't kid yourself.

DO NOT turn off the car if you get this wrench warning, you have a danger that it won’t turn on again and will be bricked. If you stop the car, much less turn it off, make sure you park nose-out because you very well might need a tow. Drive slowly, limiting power requested, to a dealership ASAP.

More later, but I gotta get some rest now that myself and my family have stopped safely now at our hotel Yes I had lots of expensive room service.

---------------

A little more from looking at FordPass.

And my two DCFC sessions:

Second charge below ended actually about 45 minutes I believe before the SVS (Service Vehicle Soon) code:

Again completely normal behavior we should be expected to do with these cars.

POWERTRAIN MALFUNCTION/REDUCED POWER



I pulled out of garage this morning and received a message “Service Soon” with a wrench displayed. Continued on to park, back-in, turned car off, LVB battery voltage was good, and received message on Fordpass, “2021 Ford Mustang-Mach E, POWERTRAIN MALFUNCTION/REDUCED POWER”. I was able to drive it back home and wrench was not displayed.



This looks identical to message that you received, Is this a precursor to HVB battery contactor problem?



Job 2 build AWD, PREMIUM that has only been DC charged 6 times to 80%, and always used level 2 charger to 80% except 3 times to 100%.

 

[EELinneman]

Here ya go, get yer popcorn and feel the junction box sizzle. Enjoy the Blippi tunes and my in-the-moment commentary (I have to work on my patience with my kids!). This is a quick edit.

I must say, you handled this a lot better than I could. And, your singing voice is pitch perfect! Seriously, best of luck and I hope that Ford realizes that this is the ideal case for them to address with a skilled, rational customer. Not all of us would hit either, let alone both, of these criteria.

 

[lonndog]

This is the third time it's happened in 2 months....we shall see

Ohhhh...

Ours was pretty weird. We'd driven it to some friends house about 3-4 miles away, all surface streets. When we got in it to leave, it threw that error. When we got home, I turned the car off, counted to 10 or something, then turned it back on. Cleared, never came back. It had also barfed out some other randomish issues earlier in the day which we missed, but were shown in the app.

 

[EELinneman]

Yeah ... not sure why that is in there or if I believe 50% of the NHTSA recall notice anyway. There's a few things in the notice that don't make sense. When the car is turned on the HVBJB contactor to the HVB is engaged and "closed". While it can weld open, the instances I've seen of that happening are when it's turned off, not in motion.

I don't think we've seen a single confirmed HVBJB failure on this forum where someone was driving along and it just flipped open and welded. Other SSN errors I think we've seen where there's electrical shorts. Maybe they do happen but if they do, It's likely to be a 0.01% chance ...

Todd,

One of the triggers appears to be DCFC. Could those extra saucy electrons cause this welded closed condition?

Sponsored