Motor Noise + Tons of issues

[jonericken]

So I’ve had my 2021 Mach-e Premium AWD Extended Range since July 2021. Didn’t have any issues until about 3,000 miles.

Issue 1: August 2021
I originally ran over something in the road (no idea what) and it dented my ENTIRE driver-side rim and tire. They replaced and it was fixed.

Issue 2: September 2021
A few weeks later, a car was turning into me while driving at 40mph so I swerve to the right and my passenger wheel goes up on the sidewalk. After that, loud thumping noises. Took into Ford dealer, where they say they replace the rim, but then drive off the lot and at 45mph+loud thumping noise/vibration is there (same as if you drive on the shoulder on highway) and is driving rougher. Especially when I am turning the wheel even slightly to the left, it is rough/has some resistance. And on acceleration/higher-speeds, it is even worse. I can feel "vibration" in the pedal and under the drivers seat/front end. After this dealership kept giving me issues and attitude, I got Ford corporate involved where a case manager took over. Corporate worked between us and came to be a new wheel barring was needed. It then was “fixed” after a month and a half. I kept asking how this was even possible and would cause this much damage, and my case manager said they had something similar happen to another Mach e.

Issue 3: December 2021
I was driving to visit my family a few hours away and noticed at higher speeds the brakes were rough as if worn. I contact my case manager and then take it into a new Ford dealership near my family where they determine the front brake pads were worn and bad. They replace them.

Issue 4: January 2022 (current)
I’ve noticed the last week that when I hit 45mph+ the motor is louder and at higher speeds there is a slight rattling in the steering wheel, driver seat, driver pedals, and driver floor. I’ve tried driving in two pedal mode and one pedal mode (my usual preference) and it produces the same results. I’ve also turned off the propulsion sound and had the sound on and still has the issue. Additionally, my SecureAlert will not switch and stay on.

All in all, not sure if anyone else has had this current issue (or previous)? I still haven’t gotten my recall handled with the windows, so was going to either just schedule something and have them look at that time and/or get my case manager involved again. I LOVE the car but these constant issues have been really making me upset because I just want the car to be reliable and work as it should, especially with the amount of money I shelled out. The current noise is noticeable and when I drive it just feels like something is off. It used to run very smooth and quiet.

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[RickMachE]

You caused the first 2 issues. Hitting a curb at 40mph did damage. No surprise. Inability of your dealership to properly fix it the first time, so pick another dealer. No idea on the brakes. They build up rust, so a hard braking cleans them off.

No idea on your current issue.

 

[ARK]

Could Issue 4 be related to Issue 2? I also agree that hitting the curb at 40mph is sort of a big deal and might have screwed up a lot more than just the wheel.

 

[BadgerGreg]

Lots of issues with the brakes, but as others mentioned, that's usually due to infrequent use. When I engage my friction brakes, I often get a bit of noise too. Once a week I turn of 1-pedal mode and exercise the brakes...that tends to clean them off and reduce the noise. It's amazing how infrequently the friction brakes are used when using 1-pedal. I wouldn't be surprised if I go 100,000++ miles without having any brake system work done.

On the motor noise, I'm guessing that you damaged other components when you hopped the curb. At that speed, I figure you knocked a few things a bit out of place. I wonder if the motor was knocked slightly out of alignment.

 

[Maquis]

There’s a TSB on the brakes. May or may not be related to your problem.

 

[Mach1E]

I LOVE the car but these constant issues have been really making me upset because I just want the car to be reliable and work as it should, especially with the amount of money I shelled out.

I’m kinda confused.

You ran over something and bent your rim, then hit a curb at 40 mph, bent another rim and messed up the car.

None of this has anything to do with the “reliability” of the car.

Your only complaint should be about the brake pads. Everything else was your fault.

Did you have to pay out of pocket to fix everything or did the dealer somehow cover the damage under the warranty? IMO only the brakes should be a warranty claim.

 

[Chiboyal]

I’m kinda confused.

You ran over something and bent your rim, then hit a curb at 40 mph, bent another rim and messed up the car.

None of this has anything to do with the “reliability” of the car.

Your only complaint should be about the brake pads. Everything else was your fault.

Did you have to pay out of pocket to fix everything or did the dealer somehow cover the damage under the warranty? IMO only the brakes should be a warranty claim.

The impact of the wheel hitting the curb may also be related to uneven wear on the brake pad. Moral of the story, try not to crash your MME! ?

 

[Logal727]

There’s a TSB on the brakes. May or may not be related to your problem.

This

 

[UsernameChecksOut]

Wondering if this could all be something a bit simpler like your rim still being bent or your tire sidewall being damaged.

I’d take the tire/rim to get looked at and rebalanced. It’s possible you’ll need a realignment too.

Here’s possibly a quick test to see if it’s related to the wheel/tire as opposed to the rest of your drivetrain — swap wheels where you move the “bad side” wheel to another corner of the vehicle and put a different “good” wheel in its place. Does it change your driving dynamics? Do you start feeling vibration/instability from a different corner now at higher speeds?

Just a few ideas.

 

[KevinS]

Everything (except for SecureAlert issue, seems unrelated) can be viewed as consistent with and a direct result of hitting the curb at 40mph.

I agree with the advice given by @UsernameChecksOut

The brake issue discussed was about pad material getting stuck to the front rotors, but since you had the brakes serviced last month that seems to rule that out.

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