Ford Recalls 234 Mach-E’s for Incorrect HVBJB Software Update, NHTSA 25V-130

[Mach-Lee]

To summarize this one, a small number of vehicles (234) were not correctly updated with the 22S41 recall software that helps prevent HVBJB failures. These vehicles will need to visit a dealer to get their powertrain software updated with FDRS to the correct/latest version. It appears the cause was due to a glitch in the FDRS software that does the updates; there have been some problems with the wrong versions of software being applied by FDRS in the past, or updates failing with errors. It's also possible the dealer claimed the 22S41 updates were complete without actually having done them. During an audit, Ford identified the vehicles in their database with software versions that did not match the recall software or later. Moving forward, Ford has added a verification step for all software recalls that ensures the correct software is present on the vehicle after an update so this doesn't happen again. The vast majority of vehicles (98.6%) had their software correctly updated.

NHTSA 25V-130
Ford 25S41

Ford hasn't released the 25S41 recall in their system yet, so don't ask your dealer, they won't know. Hopefully it's released in the next week or two. It might show up for your VIN on NHTSA's website. Your software would have to be WAY out of date to be affected by this.

Description of Defect: According to Ford’s records, certain 2021-2022 MY Mustang Mach-E vehicles did not have the remedy for Safety Recall 22S41 / 24V-412 installed correctly but were recorded as having the repair successfully completed in Ford’s records. Because the correct software update remedy may not be installed on the vehicle, the underlying condition specified in Safety Recall 22S41 / 24V-412 may still exist, and Direct Current (“DC”) fast charging and repeated wide open pedal events can cause the high voltage battery main contactors to overheat. Overheating may lead to arcing and deformation of the electrical contact surfaces, which can result in a contactor that remains open or a contactor that welds closed.

See attached for complete NHTSA Safety Recall Report.

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[Arjan]

So this recall was a bit too late for me, i need an replacement because i got the feared jailbars.

 

[Guss-E 2021]

Interesting. As it happens, my girl is at the dealership now for a SVS/Power train malfunction. Though I doubt I'm on the 234.

 

[GreaseMonkey]

My old 2022 won the lottery. Just for context: I called my dealer within a couple of hours of receiving the recall notification, and got the car repaired within 5 days (as recommended by Ford). So this likely is the earliest of batches that got released to perform recalls with.

I was notified by NHTSA directly via email a couple of days ago. Nothing from Ford yet.

I don’t own the vehicle anymore, so not an issue for me, but thought I’d share in case it helps anyone.

 

[ChehRob]

I give Ford until the end of this year to have its software under control. By that I mean many and all issues will be resolved with dispatch. Should something peculiar arise you take the car to the dealership and a few hours later fixed.

 

[WinterSky]

To summarize this one, a small number of vehicles (234) were not correctly updated with the 22S41 recall software that helps prevent HVBJB failures. These vehicles will need to visit a dealer to get their powertrain software updated with FDRS to the correct/latest version. It appears the cause was due to a glitch in the FDRS software that does the updates; there have been some problems with the wrong versions of software being applied by FDRS in the past, or updates failing with errors. It's also possible the dealer claimed the 22S41 updates were complete without actually having done them. During an audit, Ford identified the vehicles in their database with software versions that did not match the recall software or later. Moving forward, Ford has added a verification step for all software recalls that ensures the correct software is present on the vehicle after an update so this doesn't happen again. The vast majority of vehicles (98.6%) had their software correctly updated.

NHTSA 25V-130
Ford 25S41

Ford hasn't released the 25S41 recall in their system yet, so don't ask your dealer, they won't know. Hopefully it's released in the next week or two. It might show up for your VIN on NHTSA's website. Your software would have to be WAY out of date to be affected by this.

Description of Defect: According to Ford’s records, certain 2021-2022 MY Mustang Mach-E vehicles did not have the remedy for Safety Recall 22S41 / 24V-412 installed correctly but were recorded as having the repair successfully completed in Ford’s records. Because the correct software update remedy may not be installed on the vehicle, the underlying condition specified in Safety Recall 22S41 / 24V-412 may still exist, and Direct Current (“DC”) fast charging and repeated wide open pedal events can cause the high voltage battery main contactors to overheat. Overheating may lead to arcing and deformation of the electrical contact surfaces, which can result in a contactor that remains open or a contactor that welds closed.

See attached for complete NHTSA Safety Recall Report.

A Recall for the Recall

 

[Kamuelaflyer]

I give Ford until the end of this year to have its software under control. By that I mean many and all issues will be resolved with dispatch. Should something peculiar arise you take the car to the dealership and a few hours later fixed.

Good luck with that.

 

[ChehRob]

I understand it took Tesla about 6 years to get its software under good control. The MME and Lightning will have software about that old at the end of this year. If they can do it, they have a future, if not ....

 

[azerik]

I give Ford until the end of this year to have its software under control. By that I mean many and all issues will be resolved with dispatch. Should something peculiar arise you take the car to the dealership and a few hours later fixed.

In what world does this happen for anything? If this was an ICE <insert insanely expensive bespoke vehicle manufacturer here> it wouldn 't be fixed a few hours later. They might give you a bottle of bubbly and some caviar but moving you to the front of the line doesn't happen.
Ford won't miss you. They have very little control over the hundreds of thousands of vehicles out there.

 

[Mach-Lee]

My old 2022 won the lottery. Just for context: I called my dealer within a couple of hours of receiving the recall notification, and got the car repaired within 5 days (as recommended by Ford). So this likely is the earliest of batches that got released to perform recalls with.

I was notified by NHTSA directly via email a couple of days ago. Nothing from Ford yet.

I don’t own the vehicle anymore, so not an issue for me, but thought I’d share in case it helps anyone.

Thanks for that. Yeah I think there was a glitch where the software wasn’t right in FDRS during the first two weeks or something back in 2022 when the recall first came out. And your OTAs would have needed to stop working since.

EDIT: The server glitch was July 8-13 2022.

 

[phil]

I give Ford until the end of this year to have its software under control. By that I mean many and all issues will be resolved with dispatch. Should something peculiar arise you take the car to the dealership and a few hours later fixed.

Is Ford aware of the deadline?

 

[JohnFoxeSheets]

Is Ford aware of the deadline?

They are now and @ChehRob can soon expect a comment from @Ford Motor Company saying "Hi @ChehRob, this doesn't sound like the experience we want you to have. Please send us a DM with your VIN and dealership so we can look into this."

?

 

[JohnFoxeSheets]

Thanks for that. Yeah I think there was a glitch where the software wasn’t right in FDRS during the first two weeks or something back in 2022 when the recall first came out. And your OTAs would have needed to stop working since.

EDIT: The server glitch was July 8-13 2022.

Hmmm, I also got an email from NHTSA yesterday for this recall. It said, "Your vehicle MAY be involved in a safety recall..." so I went and checked their site as well as Ford's and nothing showed up for my VIN in either place. I've no idea if the NHTSA notification was generic or targeted, so I don't know if this is just a question of it lagging. As it happens, my car is at the dealership right now. With my luck I'll get confirmation that my car is part of the recall the second I return home from picking it up! ?

 

[noclue41]

Well, this would certainly explain why I've replaced 3 HVBJBs since I was supposed to have had the software fix. Definitely gonna keep an eye out for if I'm one of the lucky 234. And maybe not drive like a bat outta hell until then

 

[GreaseMonkey]

Thanks for that. Yeah I think there was a glitch where the software wasn’t right in FDRS during the first two weeks or something back in 2022 when the recall first came out. And your OTAs would have needed to stop working since.

EDIT: The server glitch was July 8-13 2022.

Lee, you are (as usual) correct. My car was produced during the last week of defective hvbjb hardware and was subject to a stop sale by Ford. The dealer had to apply the software update via FDRS before selling it to me. I took delivery on July 13th, so the update was applied within the window that you referenced. It all makes sense now.

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