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

[BMT1071]

Sounds good, but people are still breaking this design with 2022 and 2023 failures (although at a slower rate).

Define "breaking"? From the Ford /NHTSA perspective, the SSN/loss of motive power failure mode seems to be all they are really concerned about.

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[Mach1E]

Define "breaking"? From the Ford /NHTSA perspective, the SSN/loss of motive power failure mode seems to be all they are really concerned about.

If they end up sending you to the shop to replace the part…… they’re broken.

But either way I think people still have gotten SSN with the 2022-2023 part.

 

[thenew3]

I took mine in yesterday morning and the the recall popped right up while they were checking my car in. It’s already done, I pick up tomorrow as long as my charging issue is resolved.

How could you have it done when Ford hasn't released the new part and new software to dealers yet?

 

[JohnFoxeSheets]

? adequate number of grains of salt taken

Not anywhere close

 

[leeman]

I'm glad this is happening it's very clear that this was design mistake sure under normal low the current part should function fine permanently but as soon as you plug it into a situation where it goes beyond the standard specifications of the parts and goes out towards the bleeding edge of the specification it's clear that the heat causes problems this is all too common and many cars and other components where manufactures look for the cheapest part that meets a specification but the specification doesn't necessarily mean that it can maintain at the high-level of the specification they should've made parts that were on the high-end of the specification and even higher so that they would've been able to do you handle the extra heat this is so unfortunate but I'm sure they're going to repair all the cars they know are bad including mine which is already had this thing blow at once

 

[Mach1E]

How could you have it done when Ford hasn't released the new part and new software to dealers yet?

She’s from the future!!


Or the dealer is dumb and just applied the old recall software update.

 

[JohnFoxeSheets]

From the NHTSA Part 573 Safety Recall Report:

" Damage to the Extended Range and GT contactors caused by heat and accumulated wear during customer usage prior to the software update may reduce the effectiveness of the software deployed with 22S41 "

As to your point #1, the flat surfaces and removed groove create a larger surface area for current flow.

Sounds good, but people are still breaking this design with 2022 and 2023 failures (although at a slower rate).

I suspect it isn't so much larger surfaces but rather no single points that could concentrate electron flow such that over time weaknesses could develop. A edges of a groove might also be less likely to be perfectly planar resulting in high points that focus electron flow and sparking.

Two completely flat round surfaces with no variation would likely be much less likely to be deformed or to deform with use.

That's my guess, anyway.

 

[heisnuts]

I took mine in yesterday morning and the the recall popped right up while they were checking my car in. It’s already done, I pick up tomorrow as long as my charging issue is resolved.

Curious what part number is listed on your invoice showing that the recall was done.

I suspect there is a lack of communication. If you took it in for a SVS light that was a result of a HVBJB failure, the dealer would have replaced it with a remanufactured HVBJB. If there was no SVS light, I am sure you will not have a HVBJB replacement showing on your invoice.

 

[JohnFoxeSheets]

I think the jury is still out on this one. There definitely have been people with 2023s who have had the failure, though anecdotally it seems to be more likely to happen on AWD vehicles.

I'm a bit surprised that the recall doesn't include SR AWD versions - I thought the extra current required for the front motor was a large contributor to the failure.

"As of October 4, 2023, Ford is aware of 107 instances of high voltage contactor over-heating that resulted in a loss of motive power after completion of 22S41. 100 of these instances are on Extended Range or GT variants."

I guess they figure 6.5% of the loss of motive power failures are worth ignoring ?

 

[MailGuy]

Have you considered driving slower?

Given 25 mph speed limits (non school zone), it does not take much…

 

[scoopman]

I wonder how long it will take for my former pony to blow its latest HVBJB in the Rocky Mountains of Idaho ....

 

[BMT1071]

"As of October 4, 2023, Ford is aware of 107 instances of high voltage contactor over-heating that resulted in a loss of motive power after completion of 22S41. 100 of these instances are on Extended Range or GT variants."

I guess they figure 6.5% of the loss of motive power failures are worth ignoring ?

Pretty sure they are looking at the seven as a percentage of total vehicle population.

 

[JohnFoxeSheets]

Pretty sure they are looking at the seven as a percentage of total vehicle population.

I'm sure they are, but they're also looking at 107 as a percentage of the total volume. According to the NHTSA the total potential volume is
34,762 cars (which excludes SR cars). Last year's recall was for a total of
48,924 cars, so that presumably means the population of SR cars in that set is 14,162. So for ER cars the loss of motive power failure rate is 0.29%, while SR cars it's 0.05%. Both numbers are "low", but it still surprises me that the SR cars are left wafting in the wind...

 

[Mach1E]

I'm sure they are, but they're also looking at 107 as a percentage of the total volume. According to the NHTSA the total potential volume is
34,762 cars (which excludes SR cars). Last year's recall was for a total of
48,924 cars, so that presumably means the population of SR cars in that set is 14,162. So for ER cars the loss of motive power failure rate is 0.29%, while SR cars it's 0.05%. Both numbers are "low", but it still surprises me that the SR cars are left wafting in the wind...

Well that’s just the failure rate of people who had to get towed.

The HVJB failure rate is much higher including those who went into turtle mode.

If you believe some polls here, people think it’s close to 50% for GTs!

My guess is the real number is closer to 10%, but that’s a really high number either way.

 

[JohnFoxeSheets]

Well that’s just the failure rate of people who had to get towed.

The HVJB failure rate is much higher including those who went into turtle mode.

If you believe some polls here, people think it’s close to 50% for GTs!

My guess is the real number is closer to 10%, but that’s a really high number either way.

It's the failure rate of people who experienced loss of motive power. (I.e., the contactors welded open while driving.) This is the only failure that the NHTSA appears to care about since they don't appear to care about people getting stranded.

I agree that if you include the more common contacts-weld-closed failures, the rates will be much higher.

My point is that I don't think SR cars should be excluded from the recall!

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