High Voltage Battery Junction Box (HVBJB) Replacement Recall for recall HVBJB in 30,013 Mach-E

[MailGuy]

To add the pile, we lost ours (SVS) while going ~35mph on town roads. No recent (for weeks) DCFC either.

Wow and I thought I would be safe. My FE is in the list but after getting two speed camera tickets within 15 minutes from the same camera (epic fail on my part), I have to be good for the next 12 months.

For those unaware, speed cameras in AZ come with 3 points per offense and are moving violations by law. They yank your license at 8!! I got one removed in a five hour online class, but I live in an area with mobile cameras and insanely low speed limits. No joy for me right now…

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[cvk71]

I am sure someone from Ford is reading this thread so why don't they just tell us now if the part is all new or not. I'll see myself out.

 

[cvk71]

Isn't the strike UAW workers that work directly for Ford/GM? I don't think Ford UAW workers makes the parts. It's probably a 3rd party supplier that makes the parts. They are likely not part of the UAW strike.

But some of these parts suppliers may be slow because of the strike. They should switch to making extra HVBJB's so they have something to do.

 

[OldEVGuy]

It will be interesting to see how they deal with cars with replaced HVBJBs

For what it’s worth, this article says; “Owners who received the previous fix will still need the new replacement.”

https://electrek.co/2023/10/18/ford-mustang-mach-e-recall-impacts-35000-vehicles/

 

[Guss-E 2021]

So I just go off the phone with the dealership. I did not quite understand everything I was told but my take away is that the fundamental HVBJB replacement is complete. The outstanding issue is that the car still needs software updating/programming that the dealership actually cannot do. They called the engineers at Ford Corporate yesterday and are waiting for a response which can take up to 48 hours. Both interesting and frustrating at the same time.

I'll try to get a better explanation when I actually pick the car up (unless someone here already understands what is going on).

 

[BMT1071]

For what it’s worth, this article says; “Owners who received the previous fix will still need the new replacement.”

https://electrek.co/2023/10/18/ford-mustang-mach-e-recall-impacts-35000-vehicles/

That likely only refers to the software update from the first recall.

 

[BMT1071]

So I just go off the phone with the dealership. I did not quite understand everything I was told but my take away is that the fundamental HVBJB replacement is complete. The outstanding issue is that the car still needs software updating/programming that the dealership actually cannot do. They called the engineers at Ford Corporate yesterday and are waiting for a response which can take up to 48 hours. Both interesting and frustrating at the same time.

I'll try to get a better explanation when I actually pick the car up (unless someone here already understands what is going on).

Maybe they're trying to get the new recall software for your car.

 

[AKgrampy]

For what it’s worth, this article says; “Owners who received the previous fix will still need the new replacement.”

https://electrek.co/2023/10/18/ford-mustang-mach-e-recall-impacts-35000-vehicles/

That may or may not be accurate as the previous “fix” they refer to is the software patch (previous recall) which was considered the fix. Not necessarily the replacement of HVBJB from SVS and SSN errors. So yes everyone who received the software patch will need the new software but I am not sure yet that there is a HVBJB that is any newer than the ones people have been receiving since May 2022. We shall see in a short period of time though.

 

[ChasingCoral]

For what it’s worth, this article says; “Owners who received the previous fix will still need the new replacement.”

https://electrek.co/2023/10/18/ford-mustang-mach-e-recall-impacts-35000-vehicles/

? adequate number of grains of salt taken

 

[thenew3]

But some of these parts suppliers may be slow because of the strike. They should switch to making extra HVBJB's so they have something to do.

Why would 3rd party suppliers be slow because of the UAW strike? If anything I would think the 3rd party suppliers would now have more time to focus on producing these new parts. If UAW is on strike and aren't building new cars, parts wouldn't need to be allocated to the new car production line and can be allocated to the recall parts pool.

 

[generaltso]

I live in an area with mobile cameras and insanely low speed limits.

Have you considered driving slower?

 

[agoldman]

Something tells me that even when the parts begin to roll, the average Ford dealer will be either clueless, or at least backed up for months. Some dealers way more up to speed than others. Mine only has one ME tech and is several weeks out on normal checkups. Can't imagine how long this recall is going to take. It's really quite disappointing.

 

[dtbaker61]

The official NHTSA recall information clearly excludes SRs (for now):
https://www.nhtsa.gov/recalls?nhtsaId=23V687

October 13, 2023 NHTSA CAMPAIGN NUMBER: 23V687000
High Voltage Battery Contactor May Overheat
An overheated high voltage battery contactor can result in a loss of drive power, increasing the risk of a crash.
NHTSA Campaign Number: 23V687000
Manufacturer Ford Motor Company
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 34,762
Summary
Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang Mach-E vehicles equipped with an extended range battery. The high voltage battery main contactors may overheat.
Remedy
Dealers will replace the high voltage battery junction box, free of charge. Owner notification letters are expected to be mailed October 30, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S56. Vehicles included in this recall that were previously repaired under recall 22V-412 will need to have the new remedy completed.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
2 Affected Products
Vehicle

MAKE	MODEL	YEAR
FORD	MUSTANG MACH E	2021-2022

3 Associated Documents

• Defect Notice 573 ReportRCLRPT-23V687-1334.PDF 215.297KB
• Recall AcknowledgementRCAK-23V687-2260.pdf 645.504KB
• Miscellaneous Document - Chronology of DefectRMISC-23V687-5070.pdf 14.489KB

1 Associated Investigation
High Voltage Battery Contactor Failure
NHTSA ID: RQ23004
Dated opened: August 17, 2023
On June 10, 2022, Ford Motor Company (Ford) issued a safety recall (NHTSA Recall 22V-412) on 48,924 model year (MY) 2021-2022 Ford Mustang Mach-E vehicles produced from May 27, 2020, to May 24, 2022. This recall addressed high voltage battery main contactors that may overheat from direct current (“DC”) fast-charging and repeated wide-open pedal events. Overheating may lead to arcing or deformation of the electrical contact surfaces, which may result in a contactor that remains open or a contactor that welds closed. An overheated contactor that opens while driving may result in an immediate loss of motive power without re-engagement, increasing the risk of a crash.

The Office of Defects Investigation (ODI) has opened this Recall Query (RQ) after receiving 12 consumer complaints alleging a high voltage battery main contactor failure in MY 2021-2022 Ford Mach-E vehicles (subject vehicles) that were included in Recall 22V-412 and remedied prior to the reported incidents. The remedy in this recall was a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to prevent damage to the contactor, and a Battery Energy Control Module (BECM) software update to monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage.

Following the recall, Ford issued Technical Service Bulletin TSB 23-2020, to replace the High Voltage Battery Junction Box (HVBJB) on the subject vehicles. Consumers who experienced loss of motive power after receiving the recall remedy reported that their vehicle had the HVBJB replaced, as outlined in TSB 23-2020, to properly remedy the failure of the contactors. This RQ has been opened to assess the remedy of Recall 22V-412.

The ODI complaints cited above can be viewed at NHTSA.gov under the following ODI identification numbers: 11472202, 11475350, 11477025, 11479095, 11479421, 11485995, 11493140, 11510437, 11511316, 11517977, 11525550, 11526050.
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so.... my vehicle is a Select-AWD-SR
I did get the software 'recall' , it did detect damage, threw the SVS code, and I get my HVBJB replaced already.

I also was one of the few, and perhaps the first that filed a complaint with NHTSA on the topic and potential for dangerous strandings due to loss of power.

So far, the revised HVBJB has been fine.... but I think the better solution would be a 3rd revision which actually adds a chill plate, plumbing, and coolant thru the HVBJB.

 

[thenew3]

So far, the revised HVBJB has been fine.... but I think the better solution would be a 3rd revision which actually adds a chill plate, plumbing, and coolant thru the HVBJB.

That would be a pretty significant change as that would require modification to the cooling circuit. I doubt Ford would do that.

I reached out to my local dealer yesterday to inquire about the status of parts for my other recalls (windshield, sunroof, parking brake). I asked him about this new recall, he said Ford is working on a new part and new software that currently isn't available and they do not know the ETA but suspect it will be available before end of the year.

 

[MachE70]

The official NHTSA recall information clearly excludes SRs (for now):
https://www.nhtsa.gov/recalls?nhtsaId=23V687

October 13, 2023 NHTSA CAMPAIGN NUMBER: 23V687000
High Voltage Battery Contactor May Overheat
An overheated high voltage battery contactor can result in a loss of drive power, increasing the risk of a crash.
NHTSA Campaign Number: 23V687000
Manufacturer Ford Motor Company
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 34,762
Summary
Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang Mach-E vehicles equipped with an extended range battery. The high voltage battery main contactors may overheat.
Remedy
Dealers will replace the high voltage battery junction box, free of charge. Owner notification letters are expected to be mailed October 30, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S56. Vehicles included in this recall that were previously repaired under recall 22V-412 will need to have the new remedy completed.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
2 Affected Products
Vehicle

MAKE	MODEL	YEAR
FORD	MUSTANG MACH E	2021-2022

3 Associated Documents

• Defect Notice 573 ReportRCLRPT-23V687-1334.PDF 215.297KB
• Recall AcknowledgementRCAK-23V687-2260.pdf 645.504KB
• Miscellaneous Document - Chronology of DefectRMISC-23V687-5070.pdf 14.489KB

1 Associated Investigation
High Voltage Battery Contactor Failure
NHTSA ID: RQ23004
Dated opened: August 17, 2023
On June 10, 2022, Ford Motor Company (Ford) issued a safety recall (NHTSA Recall 22V-412) on 48,924 model year (MY) 2021-2022 Ford Mustang Mach-E vehicles produced from May 27, 2020, to May 24, 2022. This recall addressed high voltage battery main contactors that may overheat from direct current (“DC”) fast-charging and repeated wide-open pedal events. Overheating may lead to arcing or deformation of the electrical contact surfaces, which may result in a contactor that remains open or a contactor that welds closed. An overheated contactor that opens while driving may result in an immediate loss of motive power without re-engagement, increasing the risk of a crash.

The Office of Defects Investigation (ODI) has opened this Recall Query (RQ) after receiving 12 consumer complaints alleging a high voltage battery main contactor failure in MY 2021-2022 Ford Mach-E vehicles (subject vehicles) that were included in Recall 22V-412 and remedied prior to the reported incidents. The remedy in this recall was a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to prevent damage to the contactor, and a Battery Energy Control Module (BECM) software update to monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage.

Following the recall, Ford issued Technical Service Bulletin TSB 23-2020, to replace the High Voltage Battery Junction Box (HVBJB) on the subject vehicles. Consumers who experienced loss of motive power after receiving the recall remedy reported that their vehicle had the HVBJB replaced, as outlined in TSB 23-2020, to properly remedy the failure of the contactors. This RQ has been opened to assess the remedy of Recall 22V-412.

The ODI complaints cited above can be viewed at NHTSA.gov under the following ODI identification numbers: 11472202, 11475350, 11477025, 11479095, 11479421, 11485995, 11493140, 11510437, 11511316, 11517977, 11525550, 11526050.
Request Research (Services fees apply)

Excellent information, thanks for posting. The document you attached titled "Part 573 Safety Recall Report" indicates that the remedy will include replacement of the existing HVBJB (Part # LK98-10C666-AB for the GT models) with a new HVBJB (Part # LK98-10C666-AD for the GT models). The new part appears to be the third iteration of the HVBJB, since other previous threads reported that their failed HVBJBs were replaced with Part # LK98-10C666-AC, again for the GT models. So the part # has gone from -AB to -AC to -AD (three versions). The part #'s for the non-GT Extended Range versions appear to follow the same three version pattern.

Further, the document describes the changes in the part as follows: "The updated BEC (NK48-10C666-AC, NK48-10C666-BC, LK98-10C666-AD) design has flat contact surfaces and the groove on the movable contactor surface is removed. "

These changes don't fill me with confidence, as I would like more detail about how this solves the problem and provides a much more robust thermal management system for the contactors. Perhaps the more technical types can weigh in here about their confidence level in these modifications of the part.

This apparent third version of the part also implies that owners whose original failed HVBJB was replaced with the second version of the part will now get the third version of the HVBJB as part of this recall. This is all speculation on my part, so would welcome any other thoughts/opinions as we sort through the mess Ford has made.

Ford, if you are listening , More Information Please!

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