"Stop Safely Now" warning & start failure caused by charging system fault

[kennethjk]

To each their own, but living in fear is ridiculous to me. We took a 2,950 mile drive with the 2022 Mach-E (made before the new HVBJB) in February. The previous May we took it on a 1,045 mile trip, and in August on a 625 mile trip, followed by a 555 mile trip. I have stomped on the pedal more times than I can count.

I think “fear” is the wrong word or maybe it is for some. concern is the right word. If fear enters the equation sell the car. Luckily I have other cars and one that is more fun to WOT

fear can be paralyzing unless you can control it. Concern is being cautious and understanding the risks of what you are doing.

I for example am not paralyzed by it but my wife would be. I take the car everywhere I go but in the back of my mind I wonder will this be the time. Doesn’t stop me but.

I would absolutely drive the car to Florida on my own but if it broke down in nowheresville with my wife in the car the I told you so’s would be too much to take, LOL

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[KevinS]

All cars can leave you stranded, they’ve all got tires.

Transportation is not an issue I fret about beyond my ability to control the situation. If I maintain my vehicle and treat it right, everything should go fine. If something happens beyond my control (like a flat tire) there's nothing I can do about it.

If my tires were bald, I'd get new tires. If my car was unreliable, I'd get a new car.

 

[Mach-Lee]

Aw man, not again! ?

Weird you get yours when trying to charge in your garage with no warning. Most people get their SVS triggered from a high speed pass situation where it’s floored for 4+ seconds. Wonder if only driving around town or short throttle bursts doesn’t give it a chance to detect it or something before it welds closed?

 

[KevinS]

Aw man, not again! ?

Weird you get yours when trying to charge in your garage with no warning. Most people get their SVS triggered from a high speed pass situation where it’s floored for 4+ seconds. Wonder if only driving around town or short throttle bursts doesn’t give it a chance to detect it or something before it welds closed?

That's why I asked about what codes might be pulled from the car -- if it indicates anything different or additional about what's going on.

 

[Mike G]

I'm not sure why you quoted me. He asked about replacing the BECM which was originally what they did early on. Has nothing to do with the current reset procedure.

Sorry...I was just thinking out loud that in the event they didn't replace the BECM the last time he had this happen, and the BECM reset tool hadn't been released yet at that point, it might explain why he got another SSN this soon (assuming they never reset the counter last time).

 

[s7davis]

OP may want to look into the Lemon Laws in your state. I do believe 3x same issue qualifies for a buyback.

 

[Electric Goat]

update: After letting the car sit unplugged overnight, I was able to successfully get the car to start and drive this afternoon.

@Mach-Lee pointed me to this thread regarding how it's possible for my home charger to to cause the "Stop Safely Now" error due to a bug in Ford's software:

https://www.macheforum.com/site/thr...ng-service-vehicle-soon-while-charging.26983/

Anyway, I'm keeping the car parked outside and unplugged for a while and I'll be driving this car ONLY when my family is not with me. No matter what the cause is, it's still completely un-acceptable that starting and operating this vehicle is a constant game of Russian roulette.

 

[SoCalPony]

Is there any word from Ford or rating agencies about the rate of HVBJB failures? Seems like some communication from Ford would allay some of the fear/concern. Could be there was, but I haven't been following the HVBJB thread since the issue first broke about a year (?) ago now

SCPony

 

[Neil4Real]

They didn't release the BECM event counter reset tool in FDRS until relatively recently.

So HVJBs that were replaced but the BECM counter wasn't reset could mean that the number of counts still in memory is causing SSNs sooner than it's supposed to happen.

The smart move here is to run the BECM counter reset tool and see if the DTCs return right away.

I just received my 2nd HVBJB errors, a little over a year since my first replacement with the updated part. I was planning on doing that TSB but was advised not to by the powers that be and I need to go to the dealer and have it replaced again. I’m not really sure the true intent behind that TSB, how are dealers supposed to know when to use that versus replace the HVBJB? I think it’s only meant to be used right after the HVBJB is replaced.

To each their own, but this is pretty lame. I have a very short commute, great so cal weather, and still got another failure. I literally only drove my car to work, sat all day, then drove home from work on Friday when it happened. No meetings during the day or anything. No stomping the throttle, just bluecruise to my exit and then 40 to 50 mph to home, no throttle stomping and right before I got to my street, boom.

I am definitely now in the camp that Ford cannot fix this issue without spending crazy cash, so they don’t want to and are just letting those of us with conditions that’ll trigger replacements more than once deal with it.

I’m very fortunate that I have a great relationship with my service director, he’s already confirmed he has the part in stock and is letting me know what day he can pull their tech to do my car so I get it back same day. Others get stuck without a car for weeks sometimes. Even with my relationship, I don’t want to have to deal with this every year. I was planning a small 120 mile round trip yesterday with the wife and kids and am thankful it failed Friday. That would have been a nightmare if it failed and then further failed to a full tow situation.

 

[Mach-Lee]

FYI his SSN was caused by a P1A1E:66 code, meaning that the precharge system was activated too many times in a short period. Could be due to some kind of charging disruption that caused it to start and stop. Leaving the car off for a while allows the precharge system to reset and it will start working again. Still a scary experience that shouldn't happen.

I think his contactors are fine, this was likely caused by a charging problem.

 

[JohnFoxeSheets]

I just received my 2nd HVBJB errors, a little over a year since my first replacement with the updated part. I was planning on doing that TSB but was advised not to by the powers that be and I need to go to the dealer and have it replaced again. I’m not really sure the true intent behind that TSB, how are dealers supposed to know when to use that versus replace the HVBJB? I think it’s only meant to be used right after the HVBJB is replaced.

To each their own, but this is pretty lame. I have a very short commute, great so cal weather, and still got another failure. I literally only drove my car to work, sat all day, then drove home from work on Friday when it happened. No meetings during the day or anything. No stomping the throttle, just bluecruise to my exit and then 40 to 50 mph to home, no throttle stomping and right before I got to my street, boom.

I am definitely now in the camp that Ford cannot fix this issue without spending crazy cash, so they don’t want to and are just letting those of us with conditions that’ll trigger replacements more than once deal with it.

I’m very fortunate that I have a great relationship with my service director, he’s already confirmed he has the part in stock and is letting me know what day he can pull their tech to do my car so I get it back same day. Others get stuck without a car for weeks sometimes. Even with my relationship, I don’t want to have to deal with this every year. I was planning a small 120 mile round trip yesterday with the wife and kids and am thankful it failed Friday. That would have been a nightmare if it failed and then further failed to a full tow situation.

Damn, I'm so sorry to hear that Neil. But I'm glad you'll have it fixed without too much drama. That said, dang it sucks! I just came back from a SoCal trip and the drive up the Grapevine was a tad concerning. Luckily nothing went bad, but I do wonder when will be my turn. But hearing that you had the issue once again on your daily commute really makes me concerned... ?

 

[Rabidsquirrel22]

FYI his SSN was caused by a P1A1E:66 code, meaning that the precharge system was activated too many times in a short period. Could be due to some kind of charging disruption that caused it to start and stop. Leaving the car off for a while allows the precharge system to reset and it will start working again. Still a scary experience that shouldn't happen.

I think his contactors are fine, this was likely caused by a charging problem.

Perhaps this thread should be re-titled to the actual cause of the issue. It is probably good for more people on here to learn about this potential problem and how to address it. This is the first I've heard of it.

 

[Electric Goat]

Perhaps this thread should be re-titled to the actual cause of the issue. It is probably good for more people on here to learn about this potential problem and how to address it. This is the first I've heard of it.

Done. ?

 

[DudeWhat]

This is absolutely infuriating. My Mach-E GT has exactly 18,888 miles on it and it's essentially a sitting brick in my garage AGAIN... for the third time.

I received a charge fault notification this evening via Ford Pass and it instructed me to unplug and replug in the car and immediately my heart sank... I knew exactly what I was going to see if I attempted to start the car again. Stop Safely Now.

My last HVBJB was replaced almost exactly a year ago under the exact same circumstances.

It's official. I can't trust the car at all to safely transport my family anywhere. It's strictly been an around town cruiser for the past 8 months.

@Ford Motor Company your beefier junction box is not any better and the recall software didn't give me any advanced warning. There seriously need to be a stop sale on all of these cars. Getting stranded roughly every 6000 miles is not acceptable.

?

Edit: Updated thread title for accuracy

Wow, this is not a good thread to read since I just had mine replace (HVBJB). I dread seeing the "Stop Safely Now". I hope my repair worked.

 

[tfitzgex]

I'm on my 3rd HVBJB, first replacement one was just the original non-upgraded part, the new is the upgraded part. it didn't leave me dead like the first one did, but it put it in limp mode. Ford really really needs to fix this. It's happened to enough people that a class-action suit smells inevitable. FYI, I've got 54k on my car, in the two years I've owned it, It has been in the shop a collective 5 months...

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