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

[Shayne]

I failed to clearly make my point: I suspect that some fraction of the HVBJB have parts that are not as robust due to manufacturing variances and that those parts are not identifiable until they fail or start to fail. Thus, only a portion of the HVBJBs will fail, but impossible to identify at this point.

Again, this is only speculation, but I'm familiar with electrical part variability; every part is slightly different and perhaps some of the parts fell too far off the norm.

I disagree as it says right in the recall it is the design so for me the speculation on percentage is moot. You are grasping a straws that some were built more robust than designed and hence the design flaw is not as prevalent. That is cutting edge trying to fix a problem with higher mathematics and just does not work. You put it thru some sort of paces it going to happen. Says under designed right in the recall. The PR FAQ is just that. The part-to part variation is just leaving the door open for finger pointing that no longer goes on.

"The design and part-to-part variation of the high voltage battery main contactor is not robust to the heat generated"

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[alexgorod]

I suspect that some fraction of the HVBJB have parts that are not as robust due to manufacturing variances and that those parts are not identifiable until they fail or start to fail. Thus, only a portion of the HVBJBs will fail, but impossible to identify at this point.

Again, this is only speculation, but I'm familiar with electrical part variability; every part is slightly different and perhaps some of the parts fell too far off the norm.

You nailed it, IMO.

If it was really a design flaw, we would see a much higher failure rate than 0.5% - 1%. The only design problem (IMO again) is that it didn't take account of these manufacturing variances and variances of the power usage, and as a result, we've got the overlap that fried the contactor.

 

[Shayne]

You nailed it, IMO.

If it was really a design flaw, we would see a much higher failure rate than 0.5% - 1%. The only design problem (IMO again) is that it didn't take account of these manufacturing variances and variances of the power usage, and as a result, we've got the overlap that fried the contactor.

And it says THE DESIGN in recall why? Because Ford thought they would take the rap for the part manufacture? Thinking they may be grateful that the manufacture built it over spec a bit but that is about it. Cutting edge mathematics going on sharpen those pencils boys. Take it from a numbers guy you can not change reality with math you can just analyses and predict it. If the logic and/or math is off that math is useless. Ford is the only one that knows how far that logic/math is off. Keep the faith.

 

[tfitzgex]

Did you feel any performance throttling on your car after the update?

I haven’t noticed any. But I’m also being

Is it just held on by 3M sticky pads?

It looks like their had been glue at one point. But yeah sticky pads also. It’s happening on the other side also. The dealership I deal with is crazy busy right now. Hopefully they’ll get to me soon

 

[markboris]

Hey @scoopman, do you know specifically what the DTC was that the car showed? I just bought an OBD reader and on your advice am going to put it in the car. But I’m afraid I’ll just get a bunch on codes and have no reference for what the codes mean.

Hey Rod, in case you or anyone else is interested, here is a list of all the DTC codes for the Mach-E I put together from the repair manual.

 

[GrumblesTheDog]

I'm still curious how much pandemic-related supply chain disruptions impacted the recall fix. We (non automotive industry, for what it's worth) are still feeling shortages in pretty weird ways. If we weren't in a pandemic, would the new HVBJB be more readily available, such that hardware replacement would be offered up front? Is this to buy time to build up inventory while also serving as an early warning system? We may never know. Sorry to hear of your troubles @scoopman - hope your fix is expedited and permanent.

 

[alexgorod]

Is this to buy time to build up inventory while also serving as an early warning system?

I really hope so.

Electric cars must be too important for Ford future to let it slip into the HVBJB disaster on the very first electric model.

 

[GreenCar]

Sort of. The car had to be started after 5/25. My Orange Premium was finished on 5/25 but needed the software fix. My GTPE that started 4/20 and finished 6/15 also needs the software fix. I doubt either has the upgraded part.

Thanks for this info. Combining with reply from @scoopman, my guess is that both your MME have the upgraded redesigned part. My two cents:

1. The software fix is to prevent overheating of battery contactor. This software change is applied universally in MME made before and after 5/25 say 7/5. Since your MME left the plant before new software availability on 6/28, you have to get the software.

2. Ford must know and be confident the exact date of design/part change, that is 5/25/22. Ford knows they used the bad part 5/27/20-5/24/22. I got to trust Ford knows that for sure.

3. My guess is that MME built 5/25-6/28 have new parts and require software upgrade (I do not call "fix", since these cars should have the robust design to begin with).

4. MME built on and after 6/28 are CLAER in that they will have the new part and new software version that everyone should have after 6/28.

Please give me your opinion on this, since I am facing a dilemma of paying $5000 over MSRP for a MME premium built on 5/24 vs. wait for MME built after 5/25.
Any wisdom/help here is appreciated!

 

[Regulus7]

Please give me your opinion on this, since I am facing a dilemma of paying $5000 over MSRP for a MME premium built on 5/24 vs. wait for MME built after 5/25.
Any wisdom/help here is appreciated!

Personally I would not pay a premium over MSRP and so if you can get the post 5/25 build car at MSRP then unless I needed a new car asap then I would wait. Just my 2c

 

[guyofthesky]

They are already producing them. The inadequate ones are no longer available.

Very interesting. Thanks.

So how would I determine if the replacement I got last week was the new one or the old one? If there a part number I could look for?

 

[scoopman]

Hey @scoopman, do you know specifically what the DTC was that the car showed? I just bought an OBD reader and on your advice am going to put it in the car. But I’m afraid I’ll just get a bunch on codes and have no reference for what the codes mean.

Perhaps you should read my first post.

 

[DevSecOps]

Very interesting. Thanks.

So how would I determine if the replacement I got last week was the new one or the old one? If there a part number I could look for?

Check out this thread. First post contains most of the information you might be looking for:

https://www.macheforum.com/site/thr...ers-biggest-fear-facts-and-info-thread.18143/

 

[scoopman]

I'm still curious how much pandemic-related supply chain disruptions impacted the recall fix. We (non automotive industry, for what it's worth) are still feeling shortages in pretty weird ways. If we weren't in a pandemic, would the new HVBJB be more readily available, such that hardware replacement would be offered up front? Is this to buy time to build up inventory while also serving as an early warning system? We may never know. Sorry to hear of your troubles @scoopman - hope your fix is expedited and permanent.

I think it is doubtful that failing to offer the redesigned part is due to needing to build up inventory. The part generally seems to be available to dealers who order it when the old, underdesigned part fails.

 

[Addos]

If it is faulty manufacturing or testing from the parts supplier. Ford should be sueing to recoup the costs necessary to replace the part with a validly designed/spec'd part, as it was originally purchased to do, and for damage to the Ford brand and reputation. Trying to cover this up will create damage to the Ford brand that will be hard to recover from, especially since the Mach E is many customer's first experience with the Ford brand. This doesn't inspire confidence, or help re-assure customers who paid as much as they have for a Mach E that their money was well spent.

 

[zahidcaglioz]

So as far as i understood, if we get the error message we need to take the car to the dealer. Do we need to drive to dealer immediately or in couple of hours any idea?

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