MadManMoon
Well-Known Member
- First Name
- Drew
- Joined
- Nov 23, 2019
- Threads
- 10
- Messages
- 103
- Reaction score
- 211
- Location
- MD
- Vehicles
- 2021 Mach-E GTPE, 2007 Shelby GT500
- Occupation
- Engineer
- Thread starter
- #1
Background:
My car is a 2021 Mustang Mach-E GT Performance Edition, a Job 2 model built on December 1, 2021. At the time of the failure, the vehicle had 6,031 miles and had been in service for just over three months. I normally charge at home on a Level 2 GRIZZL-E charger (to 90% every morning, with departure times and pre-conditioning), consume roughly 10% battery on my morning commute, leave the vehicle for 8-10 hours in an uncovered parking lot (no charging available at work), then drive home consuming another 10%. I plug in as soon as I get home and the vehicle usually reaches 90% charge by 8 or 9 PM. I've only used DC Fast Charging on 3-4 long road trips since purchase, and the last time I'd used a Level 3 DC Fast Charger was 11 days prior on Sunday, April 10. At the time of failure, the battery state of charge was approximately 72%.
Thursday, April 21:
Stopped on the way home from work to do some shopping, came out to leave to find the "Stop Safely Now" error. Repeated attempts to re-start were unsuccessful. I waited 30 minutes to no avail. Called Ford's Emergency Roadside Assistance, and the first truck arrived after 30 minutes. Driver stated that because I was in a parking spot, he would need to charge an additional $100 "fee" to load. I refused and called Ford again, who dispatched another company. I had to wait an hour, but they arrived and quickly and easily backed the car into a spot where they could load. (Note I was able to get the car into Neutral using the center screen, as my 12V battery still had capacity.)
The tow driver had never loaded a Mach-E, so I was glad I'd downloaded the Towing Point PDF found on this forum. He quickly and easily got the car onto the flatbed, drama-free.
Watching her roll away from the passenger seat of my wife's F-150...
Offloaded at my local Ford dealer, luckily only a five-minute drive away.
No dealer loaners are available, so I'll be driving my 2007 Shelby GT500 to work for the foreseeable future. Not exactly a comfortable commuter car!
Friday, April 22:
My service tech wasn't able to get the car into the bay to start disassembly (he was working on a 2.3L Mustang), but was able to get all the trouble codes, which confirmed the HVBJB issue.
Monday, April 25:
New HVBJB was ordered, with a 3- to 5-day ETA. Dealer loaner was available - a 2022 Ford Edge Titanium AWD (fully loaded) - so I picked up and signed an initial agreement with an expiration of May 8. Nice, but I still miss my EV!
Monday, May 2:
Replacement HVBJB arrived. Still awaiting time on my service tech's calendar to begin repair.
Tuesday, May 3:
Repair began late in the afternoon.
Wednesday, May 4:
In-progress pictures sent by my service manager and tech. Notably, mine is the first Mach-E whose battery has been removed, hence the great interest from the entire service department!
Thursday, May 5:
Good news, bad news. Good news: HVBJB replacement complete with no issues. Bad news: pressure testing of the reassembled battery failed. Small crack found where the battery cover rises up to cover the array under the rear seat. Great quote from my tech: "Apparently these things are made of eggshells!"
Friday, May 6:
Visited dealer to inspect cracked battery cover and to sign an extension of the loaner agreement. New battery cover ordered, ETA 3-5 days. As my service manager and tech watched me carefully photograph every item with a part number, they muttered, "You are SUCH an engineer!" Guilty as charged!
Monday, May 9:
Replacement battery cover arrived...damaged from shipping. It was hapazardly loaded on a double-pallet too small for the box. Another replacement ordered, this time with "special handling" which will hopefully protect it better. Downside is, it'll likely take longer, and they can't track it's ETA. So now we're just waiting.
Wednesday, May 18:
My dealer received an intact battery cover, which came equipped with the foam blocks on the bottom (facing the battery internals), but NOT on the top, even though the parts catalog says it does, and there is no separate part number call-out for the top foam blocks. Tech is working with the Parts Hotline and a Field Service Engineer to get the blocks ordered. He was at least able to re-assemble the battery and start the leak test. Fingers crossed!
So that's where I am as ofFriday, May 13 Wednesday, May 18. This is Day 22 27 without my car. My dealer has been great every step of the way, with a loaner ASAP, timely updates, and nearly free reign to inspect things in progress. I just hope the next battery cover arrives intact!
I'm also concerned that the root cause hasn't yet been addressed - we've already seen other forum users have the same issue re-occur. I don't want another ticking time-bomb under the "hood" - I want to be able to trust my car! Apparently according to the Field Service Engineer, a TSB is on the way, but who knows how long that will take...or if the root cause will actually be fixed. Fingers definitely crossed!
I also know there's going to be a full day (or more!) of software updates once the battery is reassembled and reinstalled. I'm definitely looking forward to the charging curve improvements!
I'll update this thread as I learn more.
My car is a 2021 Mustang Mach-E GT Performance Edition, a Job 2 model built on December 1, 2021. At the time of the failure, the vehicle had 6,031 miles and had been in service for just over three months. I normally charge at home on a Level 2 GRIZZL-E charger (to 90% every morning, with departure times and pre-conditioning), consume roughly 10% battery on my morning commute, leave the vehicle for 8-10 hours in an uncovered parking lot (no charging available at work), then drive home consuming another 10%. I plug in as soon as I get home and the vehicle usually reaches 90% charge by 8 or 9 PM. I've only used DC Fast Charging on 3-4 long road trips since purchase, and the last time I'd used a Level 3 DC Fast Charger was 11 days prior on Sunday, April 10. At the time of failure, the battery state of charge was approximately 72%.
Thursday, April 21:
Stopped on the way home from work to do some shopping, came out to leave to find the "Stop Safely Now" error. Repeated attempts to re-start were unsuccessful. I waited 30 minutes to no avail. Called Ford's Emergency Roadside Assistance, and the first truck arrived after 30 minutes. Driver stated that because I was in a parking spot, he would need to charge an additional $100 "fee" to load. I refused and called Ford again, who dispatched another company. I had to wait an hour, but they arrived and quickly and easily backed the car into a spot where they could load. (Note I was able to get the car into Neutral using the center screen, as my 12V battery still had capacity.)
The tow driver had never loaded a Mach-E, so I was glad I'd downloaded the Towing Point PDF found on this forum. He quickly and easily got the car onto the flatbed, drama-free.
Watching her roll away from the passenger seat of my wife's F-150...
Offloaded at my local Ford dealer, luckily only a five-minute drive away.
No dealer loaners are available, so I'll be driving my 2007 Shelby GT500 to work for the foreseeable future. Not exactly a comfortable commuter car!
Friday, April 22:
My service tech wasn't able to get the car into the bay to start disassembly (he was working on a 2.3L Mustang), but was able to get all the trouble codes, which confirmed the HVBJB issue.
Monday, April 25:
New HVBJB was ordered, with a 3- to 5-day ETA. Dealer loaner was available - a 2022 Ford Edge Titanium AWD (fully loaded) - so I picked up and signed an initial agreement with an expiration of May 8. Nice, but I still miss my EV!
Monday, May 2:
Replacement HVBJB arrived. Still awaiting time on my service tech's calendar to begin repair.
Tuesday, May 3:
Repair began late in the afternoon.
Wednesday, May 4:
In-progress pictures sent by my service manager and tech. Notably, mine is the first Mach-E whose battery has been removed, hence the great interest from the entire service department!
Thursday, May 5:
Good news, bad news. Good news: HVBJB replacement complete with no issues. Bad news: pressure testing of the reassembled battery failed. Small crack found where the battery cover rises up to cover the array under the rear seat. Great quote from my tech: "Apparently these things are made of eggshells!"
Friday, May 6:
Visited dealer to inspect cracked battery cover and to sign an extension of the loaner agreement. New battery cover ordered, ETA 3-5 days. As my service manager and tech watched me carefully photograph every item with a part number, they muttered, "You are SUCH an engineer!" Guilty as charged!
Monday, May 9:
Replacement battery cover arrived...damaged from shipping. It was hapazardly loaded on a double-pallet too small for the box. Another replacement ordered, this time with "special handling" which will hopefully protect it better. Downside is, it'll likely take longer, and they can't track it's ETA. So now we're just waiting.
Wednesday, May 18:
My dealer received an intact battery cover, which came equipped with the foam blocks on the bottom (facing the battery internals), but NOT on the top, even though the parts catalog says it does, and there is no separate part number call-out for the top foam blocks. Tech is working with the Parts Hotline and a Field Service Engineer to get the blocks ordered. He was at least able to re-assemble the battery and start the leak test. Fingers crossed!
So that's where I am as of
I'm also concerned that the root cause hasn't yet been addressed - we've already seen other forum users have the same issue re-occur. I don't want another ticking time-bomb under the "hood" - I want to be able to trust my car! Apparently according to the Field Service Engineer, a TSB is on the way, but who knows how long that will take...or if the root cause will actually be fixed. Fingers definitely crossed!
I also know there's going to be a full day (or more!) of software updates once the battery is reassembled and reinstalled. I'm definitely looking forward to the charging curve improvements!
I'll update this thread as I learn more.
Last edited:
