Recall Reference Number: 23S56: Overheating Battery System - and cracked HVB case

[bbachrac]

I received a notice from Ford June 4th that they were ready to service our 2021 Mustang Mach-E California RT1 Recall Reference Number: 23S56

The first mistake I made was to work directly with the dealer and not schedule through Ford. Perhaps there would have been less delay in getting the parts? In any case, I couldn't leave the car until July.

I left the car July 1st. On July 11th, the dealer informed me the High Voltage Battery Case Cover had hairline fractures and needed to be replaced. Since the battery case needs to be sealed, they could not put the battery pack back together and the car would be inoperable until they received the replacement case.
Yesterday, Jul 24th, the dealer informed me that I was 90th on Ford's list for the case part and Ford could only ship 40 this week. The dealer has no idea when they will receive the case part.

I have no idea when I will get the car back. Fortunately the car has both the original battery warranty and an extended warranty. The case cracks would not have been found except for the work related to the recall. There is probably no way for owners to know if they will encounter this case crack problem some time in the future?
{Note it is pointed out in the thread below that the crack is in the case cover.}

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[Spacey]

The Mach-E is a gift that just keeps giving...

 

[HuntingPudel]

Many of us have blown up our HVBJBs and had them replaced. @heisnuts had 3 replacements. There have also been an umber of people who have had the recall performed (unfortunately, those of us who got the inferior 1st and 2nd generation parts as warranty replacements are not in the pool for the recall). Most of us have not had an issue with the main battery case being compromised. ??

 

[heisnuts]

Many of us have blown up our HVBJBs and had them replaced. @heisnuts had 3 replacements. There have also been an umber of people who have had the recall performed (unfortunately, those of us who got the inferior 1st and 2nd generation parts as warranty replacements are not in the pool for the recall). Most of us have not had an issue with the main battery case being compromised. ??

Hey, give me some credit... I was able to go through 5 replacements ?...But also had a lot of fun and learned a lot about EVs during that time. Awwww the memories.....

 

[HuntingPudel]

Hey, give me some credit... I was able to go through 5 replacements ?...But also had a lot of fun and learned a lot about EVs during that time. Awwww the memories.....

Oops... My bad 5 replacements = 6 HVBJBs... ??

They really should let you test a '24 GT with the performance upgrade on your route. I bet you can make one blow up.And if not, I might be in line for a '25 when my Options runs out.
??

 

[heisnuts]

Oops... My bad 5 replacements = 6 HVBJBs... ??

They really should let you test a '24 GT with the performance upgrade on your route. I bet you can make one blow up.And if not, I might be in line for a '25 when my Options runs out.
??

? You don't hear about as many problems with the HVBJB now, so I am sure they figured it out. I do know they took my route and were running test vehicles on it soon after mine went back. So far I am over 20,000 miles on the M3P and have not had any failures with the car or charging yet.

 

[HuntingPudel]

? You don't hear about as many problems with the HVBJB now, so I am sure they figured it out. I do know they took my route and were running test vehicles on it soon after mine went back. So far I am over 20,000 miles on the M3P and have not had any failures with the car or charging yet.

Yeah, but I'd feel more comfortable if the new cars had the @heisnuts seal of approval. ??

 

[Mach-Lee]

I received a notice from Ford June 4th that they were ready to service our 2021 Mustang Mach-E California RT1 Recall Reference Number: 23S56

The first mistake I made was to work directly with the dealer and not schedule through Ford. Perhaps there would have been less delay in getting the parts? In any case, I couldn't leave the car until July.

I left the car July 1st. On July 11th, the dealer informed me the High Voltage Battery Case had hairline fractures and needed to be replaced. Since the battery case needs to be sealed, they could not put the battery pack back together and the car would be inoperable until they received the replacement case.
Yesterday, Jul 24th, the dealer informed me that I was 90th on Ford's list for the case part and Ford could only ship 40 this week. The dealer has no idea when they will receive the case part.

I have no idea when I will get the car back. Fortunately the car has both the original battery warranty and an extended warranty. The case cracks would not have been found except for the work related to the recall. There is probably no way for owners to know if they will encounter this case crack problem some time in the future?

I can guarantee you Ford isn't shipping 40 battery cases this week. I've never heard of hairline cracks in the battery case. I bet they meant 40 HVBJBs are being shipped. Sounds like the dealer used your HVBJB for another vehicle and is making up a story about the cracked battery case as an excuse for why you have to wait for another one.

When you get your car back, you'll have to look under it to see if the battery looks brand new and shiny or not.

 

[tfitzgex]

Oops... My bad 5 replacements = 6 HVBJBs... ??

They really should let you test a '24 GT with the performance upgrade on your route. I bet you can make one blow up.And if not, I might be in line for a '25 when my Options runs out.
??

I'm on my 4th hvbjb... and a second coolant pump because a tech failed to fill my coolant levels correctly Courtesy Ford Portland... Looking at you...

 

[bbachrac]

I can guarantee you Ford isn't shipping 40 battery cases this week. I've never heard of hairline cracks in the battery case. I bet they meant 40 HVBJBs are being shipped. Sounds like the dealer used your HVBJB for another vehicle and is making up a story about the cracked battery case as an excuse for why you have to wait for another one.

When you get your car back, you'll have to look under it to see if the battery looks brand new and shiny or not.

Thanks for your note. So far I am glad to see from the comments this seems to be an isolated problem.
The dealer sent me pictures showing the crack which are attached.

I was reporting what the dealer told be about cracks in the battery case. This is a separate issue from the HVBJB part.

Here is what's involved in replacing the HVBJB. The battery case has to be opened.

Opening the battery Mach-E High Voltage Battery Junction Box Replacement
After the battery case is open Ford Mach-E Contactor Recall 23S56

 

[TheSteelRider]

I must be completely and totally blind. Can anyone draw a large red circle around the issue?

 

[VaporTrails]

I must be completely and totally blind. Can anyone draw a large red circle around the issue?

Thank You! I was going nuts. All I see is a shadow from the magic grey sealing gloop.

Edit: I see a few more spots inside the case in the PDF attachment. It probably looks more substantial in person.

 

[azerik]

Eh, who JB -welded that

I must be completely and totally blind. Can anyone draw a large red circle around the issue?

 

[TheSteelRider]

Eh, who JB -welded that

bah-dum-tss. definitely some crack involved in that post ... ?

 

[Mach-Lee]

Thanks for your note. So far I am glad to see from the comments this seems to be an isolated problem.
The dealer sent me pictures showing the crack which are attached.

I was reporting what the dealer told be about cracks in the battery case. This is a separate issue from the HVBJB part.

Here is what's involved in replacing the HVBJB. The battery case has to be opened.

Opening the battery Mach-E High Voltage Battery Junction Box Replacement
After the battery case is open Ford Mach-E Contactor Recall 23S56

That appears to be the battery cover, not the battery case. It's made of fiberglass reinforced plastic IIRC. If they handled it poorly during the repair, dropped, or stepped on it, then it can crack and need replacement. Looks like somebody tried to cover the crack with putty. That part is tucked up under the car when the battery is installed, so I'm about 90% sure somebody broke it when they were working on the battery (which I have heard of before). Perhaps during a previous repair since it looks dusty?

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