2021 Mach-E GTPE bricked with OTA update on 3/21/25

mikedmd

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TL;DR Failed OTA update disabled my 2021 Mach-E GTPE after BC update.

Long time reader but seldom post as my life with my car hasn't really been that interesting. Don't get me wrong, I love my Mach-E and got mine September 2021 and have had no issues with it in the 46k miles I've driven it so far until last Friday 3/21. So, I'm going to write my experience to add a datapoint about an OTA failed update disabling the vehicle for anyone else researching this in the future. I think it may have been the BC 1.3 update that was posted about on Wednesday, I do briefly recall seeing text on the screen about the lane changing feature but I don't remember the BC version specifically. I've seen notices for OTA updates before so it never crossed my mind I would have any issues.

I go out of town on an overnight business trip for a meeting (about 3-4 hours away from home so I figured I'd drive it). Before I get to the hotel in the evening I stop by a DC fast charger to get it up to 80% so I don't have to charge the next day and make my way to the hotel and park and check in. I get a notification on my phone that wakes me up at 2am saying the OTA update failed and the car cannot be driven and to contact a dealer as soon as possible. Unfortunately I wasn't dreaming and it actually happened.

Ford customer service was not available at that hour. And the phone number given on the "Update Not Successful" screen seems to route to Lincoln concierge after hours, which they said they could not help me. So, I call roadside assistance even though I'm at a hotel, because I figure I need to get a tow request going. No tow trucks available and the advisor suggested I wait until the morning when more tow operators are active. So I schedule a pickup for 7-9am. Knowing that tow trucks are almost as on time as doctor's offices (not their fault, I know), I figured an early start would be my best chance to at least have my car towed to a dealership during business hours so they could at least check it in.

Now that the sun is up, I am able to get ahold of Ford customer support. They give me a case number. It took a bit of struggle because the flatbed tow truck had to work its way into a compact hotel parking lot. I miss my meeting, of course. Finally made it to the dealer at 11:30am. And yes, please keep these pictures of the tow hook attachment points from this thread handy because the tow truck driver almost made the day a lot worse. That was probably one of the best things I learned from being a reader on this forum. The tow truck driver wanted to hook onto the rear of the car but I told him there were no approved rear tow hook points and he didn't believe me. He relented when I told him if the battery was damaged it would exceed his liability insurance and so he Austin Power'd his way around the parking lot so he could get to the front of my car and use the front tow hook points to load the car onto the flatbed thankfully without issue.

The dealer was great to work with. They were very sympathetic and worked me in despite a busy Friday. They tried 3 "quick" fixes which basically amounted to re-attempting the update, but each time it failed. They were going to do another fix but it would take 3-4 hours and it was already 4pm by then. So, my lovely wife was able to drop what she was doing to pick me up and we headed home leaving the car there.

Later in the afternoon, I was contacted by a ford customer service rep named Emma who said she would be my dedicated rep from here on out and gave me her email address and she would contact the dealership on my behalf to check on progress. She assured me that everything would be covered or reimbursed including a rental car while mine was being repaired.

Saturday 3/22 now back at home, I wake up to a voicemail from my service advisor at the dealership that basically said that they have to run this through their warranty department even though it's not covered under warranty (?) but their warranty department was closed being Saturday and they would be able to process it on Monday before moving forward (it sounded like they had to order a part). I gave them authorization to do whatever work was necessary because Ford said they would reimburse me even if it's not under warranty but they insisted they still had to go through this step.

Not sure if it mattered, but I do have the 100,000 mile extended warranty since this was the first EV I've owned. Still, I wasn't worried about it since Emma assured me everything would be reimbursed even if I needed to keep the rental beyond when the car was ready because I'd have to arrange time to return to the dealership which was a few hours from where I lived. Emma was very gracious and understanding. But it was still frustrating that it took so much energy to get the gears in motion for the service dept to start repairs. And I already consider myself blessed with the head start of having a same-day appointment where I've read others not even being able to bring their car in to a dealership for weeks because of appointment availability. I think the dealership had pity on me since I was out of town when it happened.

If you've made it this far, thanks for reading. I'll update the post as things move forward. I'm still comfortable driving the car afterwards. I've had it for almost 4 years now and love it. I my plan is to turn off auto-updates. I mean, aside from the HVJB replacement (it never failed on me, I just had it replaced due to the recall), the car operates fine so I don't know what an OTA update would give me that I didn't have before that would affect my daily driving.

Mike

Ford Mustang Mach-E 2021 Mach-E GTPE bricked with OTA update on 3/21/25 PXL_20250321_053702940
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Mach-Lee

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Sorry that happened to you. It's very rare to get a full OTA brick, but you do get top customer service priority from Ford corporate if it happens. They will do everything they can to get you going again, but unfortunately the dealer can often be the limiting factor. I'm sure Emma was also telling them to do whatever repairs necessary ASAP and all repairs would be reimbursed under warranty due to the special circumstances.

Although rare, my take is that there should be a way to set OTAs to install only when you're at home. You have sort of the worst case where it installs on a road trip far from home, when parked in a difficult spot for a tow, and happens on a weekend when the dealers aren't open. Personally I would recommend disabling automatic updates while you're on a road trip. Ford does need to improve the way OTAs are approved by customers so they do not install at undesirable times. We get no effective prior notification (e.g. FordPass notification) before install attempts are made. Your situation is a textbook example of why customers need more control over the scheduling of OTAs.

It took a bit of struggle because the flatbed tow truck had to work its way into a compact hotel parking lot. I miss my meeting, of course. Finally made it to the dealer at 11:30am. And yes, please keep these pictures of the tow hook attachment points from this thread handy because the tow truck driver almost made the day a lot worse. That was probably one of the best things I learned from being a reader on this forum. The tow truck driver wanted to hook onto the rear of the car but I told him there were no approved rear tow hook points and he didn't believe me. He relented when I told him if the battery was damaged it would exceed his liability insurance and so he Austin Power'd his way around the parking lot so he could get to the front of my car and use the front tow hook points to load the car onto the flatbed thankfully without issue.
Ford Mustang Mach-E 2021 Mach-E GTPE bricked with OTA update on 3/21/25 PXL_20250321_053702940


LOL, glad the "may exceed your liability insurance" line whipped him into action to do it right.
 
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mikedmd

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Haha, that GIF is exactly what I was picturing when he had to move the tow truck to the other side once we pushed the car out of the parking space. The driver was a real champ though. He used to drive 18-wheelers cross country and didn't even need me to spot him.

100% agree with your suggestions. In fact a friend of mine said the same thing--it would be great if Ford could allow us to geofence OTA updates to home similar to how we can set the maximum state of charge with our home charging station in the app. That would have massively simplified things. I suppose I just hit the bad luck lottery Friday morning.
 

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That really stinks to have that happen. I know Ford has updated their updater many times, probably to address this very issue. It would be nice if Ford could proactively contact customers whose software is outdated and strongly recommend a visit to the deal to get all of the pertinent updates applied by a tech.

It would also be nice to do it ourselves through a USB stick. Occasionally, people have bricked their phones and laptops, and each platform has a recovery method for reinstallation. EVs need the same method of recovery. Self-recovery would be good for Ford, and it's good for their customers.
 

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Oh boy, 1.3 installing as I write this - hope all goes well. At least I'm home...

The install finished in about 30 minutes. No errors reported. I drove the car in and out of the garage, again no errors. We are planning a trip to the beach next Friday, (about 65 miles each way). I must admit I'm looking forward to seeing how it drives, (and fingers crossed we don't have any problem!).
 
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mikedmd

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That really stinks to have that happen. I know Ford has updated their updater many times, probably to address this very issue. It would be nice if Ford could proactively contact customers whose software is outdated and strongly recommend a visit to the deal to get all of the pertinent updates applied by a tech.

It would also be nice to do it ourselves through a USB stick. Occasionally, people have bricked their phones and laptops, and each platform has a recovery method for reinstallation. EVs need the same method of recovery. Self-recovery would be good for Ford, and it's good for their customers.
I consider myself tech savvy, but I'm sure I can't begin to understand how complicated it can be to craft an update to target certain systems and modules and to do it safely. I mean, we're 25 years into the 21st century and printers are still a pain. But I'm totally on board for having self-recovery options via USB stick. At least like Lee said, limit updates to your home wifi network or geofence it and make it more obvious to queue an update at will instead of automatically.


Oh boy, 1.3 installing as I write this - hope all goes well. At least I'm home...
Sending you all the good vibes, hope it goes well. So far I haven't read of anyone else getting disabled recently because of an update failure. Hopefully you are in the fortunate majority.
 
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mikedmd

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Oh boy, 1.3 installing as I write this - hope all goes well. At least I'm home...

The install finished in about 30 minutes. No errors reported. I drove the car in and out of the garage, again no errors. We are planning a trip to the beach next Friday, (about 65 miles each way). I must admit I'm looking forward to seeing how it drives, (and fingers crossed we don't have any problem!).
Glad it worked for you! I'm sure that was a relief after reading my post lol.

No updates on my car yet, but it doesn't show up as "Disabled Vehicle" in the Ford app on my phone. So that's progress I hope.
 

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No updates on my car yet, but it doesn't show up as "Disabled Vehicle" in the Ford app on my phone. So that's progress I hope.
Oh that's interesting they have a FordPass status for that...
 
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Heading out tomorrow to pick up my car! Just got the message from the dealership that repairs are completed.

Here is my interpretation of the notes on the repair invoice:
  1. Diagnosis: Image Processing Module A (IPMA) failed to update during the OTA process and that's what caused it to go into inhibit mode.
  2. Tech tried to update the IPMA and it failed. They then reset the IPMA learned values and tried again and it failed.
  3. Following TSB 23-2170, they discovered that the IPMA update issue could be caused by other modules not being up to date. So they updated several modules (PCM, BECM, SOBDMB, SOBDMC, SOBDM, ABS, PSCM, etc...) but the IPMA still failed to update.
  4. So they then attempted a LIN new module initialization and IMPA configuration which also failed.
  5. Finally, they performed an IMPA Programmable Module Installation (PMI) which successfully updated the IPMA. Then they were able to reset the OTA inhibit mode, do an IPMA alignment, and 360-degree view camera alignment. Test drove it. Charged. Test drove it again the next day.
I read in other posts where a car became inoperable after an OTA update and it was a simple reupdate procedure that fixed it. Apparently I indeed got the unlucky lottery and I am very appreciative of the technician's persistence in being able to correct the issue.

Sorry that happened to you. It's very rare to get a full OTA brick, but you do get top customer service priority from Ford corporate if it happens. They will do everything they can to get you going again, but unfortunately the dealer can often be the limiting factor. I'm sure Emma was also telling them to do whatever repairs necessary ASAP and all repairs would be reimbursed under warranty due to the special circumstances.
I can verify this! Once you speak to the right person and Ford customer service understands what exactly happened, you'll get very high priority customer support. Also, the bill for the repair was a nice $0.00. So the warranty department came through.

Also this was unexpected... Ford sent me 100,000 Fordpass points. The name for the points package caused me to chuckle.

Ford Mustang Mach-E 2021 Mach-E GTPE bricked with OTA update on 3/21/25 5fd95c8e-7574-4d07-8803-fddcd6ff15ca



Hope this thread was informative for anyone who might be going through something similar.


Edit: 4/3/2025 - Got the 10.1.0 update! This was the original one that disabled my car. Nice to see it installed after the ordeal.
 
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ericNdfw

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My 2021 Premium just had this happen. Got the same Lincoln desk on the line when I called and they transferred me to someone from Ford who, after multiple times on hold, told me to call the local dealer service department. Of course, it's 7:15pm so they are closed for the day too. I certainly hope they don't try to charge me for anything on this.
 
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mikedmd

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My 2021 Premium just had this happen. Got the same Lincoln person on the line when I called who transferred me to someone from Ford who, after multiple times on hold, told me to call the local dealer service department. Of course, it's 7:15pm so they are closed for the day too. I certainly hope they don't try to charge me for anything on this.
Oof, I feel your pain--literally. They won't charge you or will at least reimburse you afterwards. Once you finally get ahold of someone, they'll likely assign you a dedicated rep who will follow you through the end. The key is to get your car towed to a dealership with a good service center. If you do spend anything for your inconvenience, save receipts. I was refunded for a course tuition (a couple hundred $$) that I missed for a seminar I was suppose to attend on a business trip along with a rental car replacement. So you'll get well-taken care of, just sucks to go through.
 
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ericNdfw

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I believe it was the initial call to Ford's 800 number that got that set up.
Is that the same 800 number on the screen? If so, I'll try it tomorrow morning.

I'm so glad this didn't happen to me on the road like you had to deal with!
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