NHTSA investigating 2022 Mach-E HVBJB recall (high voltage battery main contactors)

[DevSecOps]

folks that are hanging their hopes on NHTSA resolving product merchantability and fitness issues around the HVBJB failures are going to be sorely disappointed.

the "S" in NHTSA stand for safety (not product liability) and the key sentence in their notice is:

also notice that there are only 12 "complaints" in the report summary. no other specific report types (crash/fire, injuries, etc) but 44 "others" which are nebulous "Early Warning Reporting Field Reports". the lack of actual crashes, fires, and injuries is good in general but also shows it may not be a "safety" issue that will go as far as requiring physical fix or replacement.

so, they will be investigating the safety aspects and determine next steps if warranted. we may never see the details.

if y'all would send in actual documented complaints they would have more to go on. hate to break it to you but complaining on MachEForum doesn't count. ?

This is all so wrong in many ways...

First, there's a lot more than 12 that they are investigating. 12 just initiated a renewed interest. You'll see the TBD under manufacturer. Once the investigation team gets more data from Ford this TBD should be updated to a fairly large number.

Second, yes they are taking failure as a safety issue. This is because some people have lost motive power on the freeway. It isn't the job of NHTSA to redesign the part, it's their job to ensure Ford remedies the safety aspect. They entrusted them the first time and found that they might have been bit in the ass. Could that mean another software update, sure it could, but it could also mean a new part and replacements. Once the investigation is complete we will know. The safety aspect was investigated the first time and found to be a legit issue. There's no need to re-investigate that. This is not a new investigation into a new issue. It's an investigation in the adequacy of the original recall.

Third, Federal DOT (NHTSA) investigators have reached out to people on this forum. Posting stuff here does get noticed especially when forum posts are referenced in formal complaints.

Lastly, when this recall first hit the forum was filled with Fanboys and skeptics alike. It was very contentious. Some people attempted to gather together members to file NHTSA complaints but it was often met with discouragement and negativity (here's one example).

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[kodiakng]

But internet....

truly. it's astounding how many NHTSA experts we have here now though... ?

 

[dtbaker61]

More information straight from NHTSA:

https://static.nhtsa.gov/odi/inv/2023/INOA-RQ23004-4752.PDF

I am disappointed to see just 12 complaints.

I can't believe i am only 1 of 12:64,727 owners concerned enough to file a complaint regarding the possible consequences of suddenly losing power, steering, or brakes, or getting stranded in bad weather or on a dangerous stretch of highway?

maybe if several THOUSAND complaints are filed NHTSA will take it seriously and require a more robust redesign and a 'real' hardware recall....

But, happy to see zero deaths, injuries, fires, etc. so far


I'd really like to know how many v1 HVBJB were physically replaced, and how many v2 have failed after replacement. Mine (AWD Select SR) was replaced about 10k miles ago and seems to be holding up.

 

[kodiakng]

I am disappointed to see just 12 complaints.

I can't believe i am only 1 of 12:64,727 owners concerned enough to file a complaint regarding the possible consequences of suddenly losing power, steering, or brakes, or getting stranded in bad weather or on a dangerous stretch of highway?

you along with @scoopman means macheforum accounts for 1/6 of the complaints so far. we can definitely get the numbers up if folks with an actual failure provide input.

 

[DevSecOps]

I am disappointed to see just 12 complaints.

I can't believe i am only 1 of 12:64,727 owners concerned enough to file a complaint regarding the possible consequences of suddenly losing power, steering, or brakes, or getting stranded in bad weather or on a dangerous stretch of highway?

And it's sad that you were ridiculed when you asked people to join you. I hope when they all get replacement HVBJB's they'll thank you and everyone who worked with NHTSA to help get this issue resolved.

 

[dtbaker61]

you along with @scoopman means macheforum accounts for 1/6 of the complaints so far. we can definitely get the numbers up if folks with an actual failure provide input.

I filed a complaint BEFORE my HVBJB failed because I was concerned with the possible safety issues of unexpected and total loss of power.

The software early warning 'recall' worked in my case, and prevented bricking.... but to me the safety issue remains for anyone who did not get the software update, or if the software doesn't happen to catch a failure in time and reduce power output.

Now the reports of second generation HVBJB failures has my attention. I'd like to know the numbers....

I do think it would be good for any and all of the 65,727 owners at risk to file complaints and request a hardware fix and recall.

 

[dtbaker61]

And it's sad that you were ridiculed when you asked people to join you. I hope when they all get replacement HVBJB's they'll thank you and everyone who worked with NHTSA to help get this issue resolved.

I'll just renew my suggestion that Members consider filing a complaint. Links and other info is here: https://www.macheforum.com/site/thr...vbjb-to-get-a-better-recall-than-22s41.19404/

 

[kodiakng]

I filed a complaint BEFORE my HVBJB failed because I was concerned with the possible safety issues of unexpected and total loss of power.

The software early warning 'recall' worked in my case, and prevented bricking.... but to me the safety issue remains for anyone who did not get the software update, and now the reports of second generation HVBJB failures has my attention. I'd like to know the numbers....

I do think it would be good for any and all of the 65,727 owners at risk to file complaints and request a hardware fix and recall.

agree in total. in addition, those with actual failures will add specific safety impact information to the investigation so they'll have added impact.

 

[superdave80]

Makes no sense. So they know how to fix it and won’t replace the bad part with a better part and keep having replace replacements , that’s costing money. or it’s way more than just 1 part, they have to replace an entire electrical system?

It's just one part, but you have to remove the entire battery pack to replace it. If they can get away with just fixing the failed parts as they fail, its WAAAAY cheaper than replacing the relay in the entire fleet of Mach-Es, even if some of them fail again. They are just trying to get us to the end of the 8 year/100k warranty without breaking the bank.

 

[BMT1071]

truly. it's astounding how many NHTSA experts we have here now though... ?

Ain't that the truth. I commend you for your delicate phrasing.

 

[Kamuelaflyer]

I am disappointed to see just 12 complaints.

I can't believe i am only 1 of 12:64,727 owners concerned enough to file a complaint regarding the possible consequences of suddenly losing power, steering, or brakes, or getting stranded in bad weather or on a dangerous stretch of highway?

The forums are not a valid cross section of Mach-e owners. The vast majority of owners experiencing an HVBJB failure are going to be angry and upset. They’ll take the car to the dealer and it gets fixed. They move on. If it happens again they may get real angry and might simply move on to another car. Others will get it fixed a second time because perhaps they had the original part as a replacement. Others have the Bullwinkle outlook. Most folks will sell, get a new car or or relegate this one to the back burner until they can afford or need to dump it. Very, very few will actually file a complaint.

The Bullwinkle outlook:

 

[Secret Sauce]

You would think so but they have yet to prove it

Suspect it's about cost. We don't have any idea what percentage of the cars are actually affected, but in a recall it won't matter, Ford will have to pay to have the part replaced in every last one of them. Again, similar to the Chevy Bolt situation. That was a billion dollar recall.

 

[AKgrampy]

Suspect it's about cost. We don't have any idea what percentage of the cars are actually affected, but in a recall it won't matter, Ford will have to pay to have the part replaced in every last one of them. Again, similar to the Chevy Bolt situation. That was a billion dollar recall.

About a $200 million recall. However you would subtract the replacement costs of any vehicles that have already had the HVBJB replaced. Unless they would be required to engineer a new HVBJB and replace every one sold to date.

 

[AKgrampy]

The forums are not a valid cross section of Mach-e owners. The vast majority of owners experiencing an HVBJB failure are going to be angry and upset. They’ll take the car to the dealer and it gets fixed. They move on. If it happens again they may get real angry and might simply move on to another car. Others will get it fixed a second time because perhaps they had the original part as a replacement. Others have the Bullwinkle outlook. Most folks will sell, get a new car or or relegate this one to the back burner until they can afford or need to dump it. Very, very few will actually file a complaint.

The Bullwinkle outlook:

If I did not participate in the forum I would not even know of the issue. I own a 22 GT now for 17 months with 13,000 miles and zero issues. I drive mostly around town with my Mach and just am not concerned about the HVBJB failing. When it does I will take the car in for repairs. If I drove long distances or if it were my only car I may be more concerned. My thought is many owners are just not having issues like myself or are on the forum so are not even aware of the HVBJB issue.

 

[stealthytolkien]

If I did not participate in the forum I would not even know of the issue. I own a 22 GT now for 17 months with 13,000 miles and zero issues. I drive mostly around town with my Mach and just am not concerned about the HVBJB failing. When it does I will take the car in for repairs. If I drove long distances or if it were my only car I may be more concerned. My thought is many owners are just not having issues like myself or are on the forum so are not even aware of the HVBJB issue.

Scientifically speaking, once you’re on the forum and know about the issue, your car gets it within 6 months. Otherwise never.

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