2023 Mach-E GT Contactor Stuck

areacode413

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So 21’, 22’, 23’ HVJB are sheet. Ford says, just keep making them. As long as they are selling, we can recall them later. Tesla’s are sounding better and better lol.
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If the part number remains the same then there will be no change. The reality is it will take a major design change to do anything significant hardware-wise with the HVBJB. Tight space, no active cooling, no active temp measurement. We hear so much about what not to do, WOT and minimize DCFC, but my personal belief is these actions cause may cause failure after damage occurs. I am not so sure they are what cause the damage. I did not have a problem with my 22GT and I certainly hope I do not have a problem with the new part!
it’s not a problem until it’s all of the sudden a problem.
 

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it’s not a problem until it’s all of the sudden a problem.
The difference for me though is I will more than likely give a 350 mile drive to Anchorage a go this summer with the new part. Even though I did not worry driving around town with the original I just did not think it was worth the risk driving long distance as there are sections of road with no cell service.
 

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Well shit- dealer said the replacement part number for me is BR for the remanufactured - wtf Ford how is this still not the latest
Damn, I hope it’s just the part number in their ordering system. When the -B part came out, the part number in the system was still -A. The parts the dealers received were -B parts. Not sure is this is the case with the current system, but I hope they have purged all of the second generation parts from inventory like they did with the first generation parts. Maybe I will wait to try to blow mine up until there is confirmation that warranty replacements are at least -C parts Since I have a -BRM part. ??
 
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If the part number remains the same then there will be no change. The reality is it will take a major design change to do anything significant hardware-wise with the HVBJB. Tight space, no active cooling, no active temp measurement. We hear so much about what not to do, WOT and minimize DCFC, but my personal belief is these actions cause may cause failure after damage occurs. I am not so sure they are what cause the damage. I did not have a problem with my 22GT and I certainly hope I do not have a problem with the new part!
My thoughts on this is that Ford produced a vehicle with the Mustang name and stamped a GT badge on it but then tells owners that we should drive it as if it were a Ford Pinto. I purposely picked the Ford Pinto because it was one of the most POS vehicles Ford ever made. Question is, will the Mach-E go down in history as today's Pinto?
 


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Well shit- dealer said the replacement part number for me is BR for the remanufactured - wtf Ford how is this still not the latest
That's not very reassuring. BTW, are you in AZ? I read Gilbert for your location.
 
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Mine has failed every year around July/August, so I'm getting close to getting the "better" part. It would be my third replacement. Lemon Law at that point? Take advantage of tanking prices and get a brand new 2024?!?
This is really a type of brand damage for Ford. The question is do they really care? I personally wouldn't put good money behind bad money and buy a newer model.
 
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Literally had the same issue 23 GT (1400mi) today and same contactor closed codes
-vehicle towed to dealer - said will look at tomorrow but looks like HVBJ

Screenshot_20240404-141107.png
I purposely waited for the 2023 model year because it was publicized that the recall was only for 2021 & 2022. It's pretty upsetting to learn that Ford continued (and possible is still continuing) to use a known-faulty element is their vehicles.
 
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At least it will be covered under warranty!
That may be so, but it still is not very good customer satisfaction. I purchased a brand new vehicle thinking I would have peace of mind and not have to worry about major mechanical issues so soon. My Mach-E is barely 1 year old and just in the 12K mile mark. When I consider my automobile ownership history since the 1990s, this is the first vehicle where I have had a catastrophic failure so soon.
 

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My thoughts on this is that Ford produced a vehicle with the Mustang name and stamped a GT badge on it but then tells owners that we should drive it as if it were a Ford Pinto. I purposely picked the Ford Pinto because it was one of the most POS vehicles Ford ever made. Question is, will the Mach-E go down in history as today's Pinto?
Ford designed a compliance car to replace the outgoing Fusion. They got the bright idea to name it the way they did and then had to re-do a lot of stuff. Part of what didn’t get changed was the HVBJB and mow we’re stuck with a form factor that cannot handle what the drivetrain demands, given normal production tolerances. Of course, they also released the “so fast it made me sick” video. ?‍♂?
 
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A contactor is to an EV as a fuel pump is to an ICE vehicle. It is in effect a single point of failure. A component as such should be designed well above minimum specifications.

When Ford realized the issue back in 2022, they should have at the least redesigned the high-voltage battery housing to make the contactors more easily accessible and safe to replace. If I were in charge, I would have an access panel and a local hard-disconnect for the HV battery. BTW, there are fuses buried within the HVBJB as well! Who the heck designed that?

If you haven't already seen it, Professor John Kelly of Weber State University has some excellent videos specifically on the Mach-E GT. Here's the link to the one focusing on contactors:
 

Just Lurking

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If the part number remains the same then there will be no change.
Do we know with confidence if the part number has changed for '24 models? I agree that will be the first indication.

The reality is it will take a major design change to do anything significant hardware-wise with the HVBJB. Tight space, no active cooling, no active temp measurement.
If Ford is willing to pay for a more expensive part I'm sure there are ways to make it more robust within the current packaging limitations. Time will tell whether the '24 has any improvements.
 
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it’s not a problem until it’s all of the sudden a problem.
$60K+ vehicle with inferior quality assurance. I'm sure Jim Farley is very proud.
 
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Damn, I hope it’s just the part number in their ordering system. When the -B part came out, the part number in the system was still -A. The parts the dealers received were -B parts. Not sure is this is the case with the current system, but I hope they have purged all of the second generation parts from inventory like they did with the first generation parts. Maybe I will wait to try to blow mine up until there is confirmation that warranty replacements are at least -C parts Since I have a -BRM part. ??
I gave up my SRT Dodge Charger for this Mach-E. That Charger faced some strenuous conditions and still ran like a champ. It wouldn't blow up even if I tried. I'm not in my happy place.
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