POST Recall Software HVBJB Failure

[Neil4Real]

Well, it was finally my turn it seems. I completed the recall software updates via FDRS last week and noticed nothing adverse after the updates and then today I got the dreaded “Service Vehicle Soon” message.

For background, I never DCFC and never have with my GTPE. I purely level 2 charge to 90% every night.

I have a very short commute to work of about 15 miles that is 90% highway and slightly hilly, but nothing really crazy like @scoopman experienced. If anyone is curious, it is the 73 toll road in Orange County.

The failure occurred on my way home from work after my car sat all day in my office’s parking structure that kept it pretty cool. Ambient temps were in the low to mid 70’s on my way home. I had used BlueCruise the whole way set to 75 and had only “gassed it” slightly at the toll booth when BC disengages.

I then exited the freeway and “gassed it” one more time, from roughly 30 mph to 40 to pass someone. Shortly after the pass I received the SVS message and my power was severely limited to the same as @scoopman

Please note, neither of the power events were in anyway pedal to the metal or anywhere close to maxing my power meter.

I ended up going home as it was after 5pm. I turned it off and on a few times and was able to drive with the same messages and power limits in place. I just tried it again and am getting the same. Hopefully it works tomorrow.

I called a few dealers and got nowhere. They all said they’re booked out for weeks. I tried explaining but the appointment people wouldn’t budge. I emailed and left a voicemail for the GM of my preferred dealer, Tuttle Click Ford in Irvine, and hope I’ll hear from him or else I guess I just call Ford corporate and see what they can do?

Pretty bummed it finally happened to me but am also happy I’ll get the beefier part. The only concern is if I can get service! Pretty crazy this is gong on and Ford hasn’t told dealers to get people with issues like this in pronto.

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[ZuleMME]

Not giving me confidence for my trip to Vegas on Sunday!

 

[JohnFoxeSheets]

Damn, so sorry to hear this happened to you, but at least relieved to know that the car could be restarted. At least there's that. I sure hope Tuttle comes through for you pronto. If not, (try to) get Ford to help you find a dealership. That's how I found Putnam here in the Bay Area, and they've been truly excellent.

Best of luck!

BTW, it is interesting that both you and Andy had done your updates via FDRS. That's likely not indicative of anything (e.g., it could very well be that it's just that you are two of the earliest users of the new s/w), but interesting just the same...

 

[Neil4Real]

Damn, so sorry to hear this happened to you, but at least relieved to know that the car could be restarted. At least there's that. I sure hope Tuttle comes through for you pronto. If not, (try to) get Ford to help you find a dealership. That's how I found Putnam here in the Bay Area, and they've been truly excellent.

Best of luck!

BTW, it is interesting that both you and Andy had done your updates via FDRS. That's likely not indicative of anything (e.g., it could very well be that it's just that you are two of the earliest users of the new s/w), but interesting just the same...

I mean, FDRS is what the dealers use, like the exact same thing. So it can’t be indicative of anything, other than the fact the software is possibly shooting out false positives.

I’ve never even DCFC, so it’s pretty crazy mine hit, since they’re making it seem like it can be avoided.

It is great I was able to still drive and hopefully can tomorrow, but I now almost wish I had to get a tow so I could get better support for the fix.

I think my situation is a perfect example that @DevSecOps is on the money that at least GT/GTPEs need the part. It’s probably way more rare in the other trims where they can wait for the software to flag them. But never even DCFC and I get hit with it on a 15 minute drive?!? Insane. This is legit, 100% normal driving conditions and the software/HVBJB can’t handle THAT? Come on.

No need to speculate if it was already hot from charging, if one pedal regen caused excessive heat, if multiple short trips contributed - nothing. Just a normal drive.

 

[DevSecOps]

I think my situation is a perfect example that @DevSecOps is on the money that at least GT/GTPEs need the part. It’s probably way more rare in the other trims where they can wait for the software to flag them. But never even DCFC and I get hit with it on a 15 minute drive?!? Insane. This is legit, 100% normal driving conditions and the software/HVBJB can’t handle THAT? Come on.

I can admit that I'm probably a little over the top on the "f-this software", but it's because of what I know was supposed to be done. It's upsetting to me that it's essentially smoke and mirrors to placate people. To me, a bricked HVBJB, is a bricked HVBJB regardless of driving to a dealer or unable to start at work. I feel like there's a lot of apologists here that keep saying this is a win for us. I just don't think that one bit. A win would be Ford doing the right thing and replacing our HVBJB's before they fail, not giving us software to let them fail.

 

[JohnFoxeSheets]

I mean, FDRS is what the dealers use, like the exact same thing. So it can’t be indicative of anything, other than the fact the software is possibly shooting out false positives.

I’ve never even DCFC, so it’s pretty crazy mine hit, since they’re making it seem like it can be avoided.

It is great I was able to still drive and hopefully can tomorrow, but I now almost wish I had to get a tow so I could get better support for the fix.

I think my situation is a perfect example that @DevSecOps is on the money that at least GT/GTPEs need the part. It’s probably way more rare in the other trims where they can wait for the software to flag them. But never even DCFC and I get hit with it on a 15 minute drive?!? Insane. This is legit, 100% normal driving conditions and the software/HVBJB can’t handle THAT? Come on.

No need to speculate if it was already hot from charging, if one pedal regen caused excessive heat, if multiple short trips contributed - nothing. Just a normal drive.

I agree on all points. I was more thinking that perhaps there might, maybe, but not likely, be something non-obvious about the manner in which the updates needs to be applied (though I know even that is highly unlikely). Anyway, I understand your frustration.

As for maybe having better luck if you car had been towed, from the experience of others (and my own), I don't know that makes much of a difference. Those that have had their cars towed haven't necessarily had more timely repairs. Besides, clearly having only 30% power is not appropriate at all.

 

[JohnFoxeSheets]

I can admit that I'm probably a little over the top on the "f-this software", but it's because of what I know was supposed to be done. It's upsetting to me that it's essentially smoke and mirrors to placate people. To me, a bricked HVBJB, is a bricked HVBJB regardless of driving to a dealer or unable to start at work. I feel like there's a lot of apologists here that keep saying this is a win for us. I just don't think that one bit. A win would be Ford doing the right thing and replacing our HVBJB's before they fail, not giving us software to let them fail.

I totally agree Todd that a 100% failed HVBJB and a not-quite-yet failed HVBJB are both really bad. And I completely agree as well that Ford should f-ing fix all cars with a part that doesn't fail. (I don't say the new part, since we don't yet know if that in fact actually doesn't fail.)

But I think you'd agree that if Andy had, for instance, pulled into a rest stop shortly after his last acceleration event, and then in the 100° SoCal heat got a SSN message instead of the SVS message he got while driving, the situation could have been much worse for him and his family with his two small children - Waiting who knows how long for a tow; not having a way to get to the hotel, etc.

Don't get me wrong: Ford should never have positioned this s/w as a fix. At most they should positioned it as a stop gap measure to help them triage the cars that needed attention first, while in the process of replacing all HVBJBs and doing that in a way that would not leave the drivers totally stranded. Had they shown that level of transparency, I think we'd all feel better.

 

[Mach-Lee]

Here's the profile for CA-73:

It's another steep 6% grade like the grapevine, just much shorter, 3 miles up vs. 15 miles for the grapevine. Shouldn't be a problem for a modern vehicle. The hills would heat things up a little bit. Just a theory, but driving to work on this route everyday could have gradually damaged the weak contactors over time? Or it's just sensitive? I'm really curious to see how things go after you and scoopman get your car back and drive it normally for a few weeks.

 

[scoopman]

Well, it was finally my turn it seems. I completed the recall software updates via FDRS last week and noticed nothing adverse after the updates and then today I got the dreaded “Service Vehicle Soon” message.

For background, I never DCFC and never have with my GTPE. I purely level 2 charge to 90% every night.

I have a very short commute to work of about 15 miles that is 90% highway and slightly hilly, but nothing really crazy like @scoopman experienced. If anyone is curious, it is the 73 toll road in Orange County.

The failure occurred on my way home from work after my car sat all day in my office’s parking structure that kept it pretty cool. Ambient temps were in the low to mid 70’s on my way home. I had used BlueCruise the whole way set to 75 and had only “gassed it” slightly at the toll booth when BC disengages.

I then exited the freeway and “gassed it” one more time, from roughly 30 mph to 40 to pass someone. Shortly after the pass I received the SVS message and my power was severely limited to the same as @scoopman

Please note, neither of the power events were in anyway pedal to the metal or anywhere close to maxing my power meter.

I ended up going home as it was after 5pm. I turned it off and on a few times and was able to drive with the same messages and power limits in place. I just tried it again and am getting the same. Hopefully it works tomorrow.

I called a few dealers and got nowhere. They all said they’re booked out for weeks. I tried explaining but the appointment people wouldn’t budge. I emailed and left a voicemail for the GM of my preferred dealer, Tuttle Click Ford in Irvine, and hope I’ll hear from him or else I guess I just call Ford corporate and see what they can do?

Pretty bummed it finally happened to me but am also happy I’ll get the beefier part. The only concern is if I can get service! Pretty crazy this is gong on and Ford hasn’t told dealers to get people with issues like this in pronto.

I would physically drop it off at your dealer and show them the DTC codes and have them give you a rental car.

Your car is supposed to be left drivable to get it to a dealer but not for you to continue to use it on the I-73 toll road for weeks.

Your dropping a car off with an undrivable critical issue will start the 30 day clock during which in California they must fix your car, or Ford has to buy it back.

Do not wait for an appointment, drive it physically there and show them that Ford Pass message and make them give you a rental.

I think if enough owners start doing this this might get Ford's attention they are not handling this properly.

Also start a case immediately with Ford via their 24/7 CS line or by having @Ford Motor Company reach out tomorrow in this thread and claim that this isn't the experience they'd like for you to have. The case is how Ford tracks what happens with your car at the dealer and how they reimburse costs to you, apparently.

 

[scoopman]

I can admit that I'm probably a little over the top on the "f-this software", but it's because of what I know was supposed to be done. It's upsetting to me that it's essentially smoke and mirrors to placate people. To me, a bricked HVBJB, is a bricked HVBJB regardless of driving to a dealer or unable to start at work. I feel like there's a lot of apologists here that keep saying this is a win for us. I just don't think that one bit. A win would be Ford doing the right thing and replacing our HVBJB's before they fail, not giving us software to let them fail.

With what they wound up doing and not doing, none of the dealers are basically prepared for the stream of our cars that will continue to fail over the in-service life of the unfixed cars.

 

[ARK]

It’s a bit of a drive from you, but when I had to schedule service for my panoramic roof/windshield recall, Sunrise Ford in North Hollywood (not Fontana) about a month ago, they were giving me appointments a few days out.

Also, if they say the part is backordered, they may let you order it yourself from another dealer anywhere in the country that has it (if Ford will reimburse?). They played ball with me on this for a pano roof I needed replaced (ultimately went through them because no dealer would ship a pano roof even though they were pricey, but I think a HVBJB doesn’t have this problem).

 

[DevSecOps]

Here's the profile for CA-73:

It's another steep 6% grade like the grapevine, just much shorter, 3 miles up vs. 15 miles for the grapevine. Shouldn't be a problem for a modern vehicle. Just a theory, but driving to work on this route everyday could have gradually damaged the weak contactors over time? Or it's just sensitive? I'm really curious to see how things go after you and scoopman get your car back and drive it normally for a few weeks.

I drive these 3 routes every week. I can almost guarantee that if I flash this software I'll get failure if it's based on elevation changes:

Altamont Pass:

Pachecho Pass:

Echo Summit:

 

[scoopman]

I drive these 3 routes every week. I can almost guarantee that if I flash this software I'll get failure if it's based on elevation changes:

Altamont Pass:

Pachecho Pass:

Echo Summit:

OTOH perhaps these are not false positives from the software.

 

[BigMach-E]

@Neil4Real I can't say definitely, but I'm rather certain that I have the "new" part. Replaced at 8.4k miles. I'm at 14.7 k miles. Although I have a SR Select AWD, I've WOTed like hell since that time. I've DCFCed probably about 10 times since replacement. I do believe it's a "fix". The software update is garbage. As Todd and scoop have stated, it's not a "fix". I'm glad you can turn the car off and on, being able to drive a turtled car, that's an improvement to being bricked/having your AGM die.

I agree, the best course of action is call a dealership, when they say "we don't have appointments anytime soon" and "we don't have loaners available" say "cool, I'm coming over there to drop my car off now, you can deal with it". Call Ford Corporate. Get a case made. Get a rental. Keep your receipts.

 

[Guss-E 2021]

I think if enough owners start doing this this might get Ford's attention they are not handling this properly.

Also start a case immediately with Ford via their 24/7 CS line or by having @Ford Motor Company reach out tomorrow in this thread and claim that this isn't the experience they'd like for you to have. The case is how Ford tracks what happens with your car at the dealer and how they reimburse costs to you, apparently.

Yes, thank you. I totally agree. I truly hope Ford monitors this forum. I have my software update appointment tomorrow morning (7/8). Fortunately, I have not had an issue yet with my Premium AWD ER. I have been, sadly, avoiding DCFC and aggressive acceleration just to be safe.

Thanks to these posts, I feel a lot better informed about the entire issue so thanks (and sympathies) to @Neil4Real and @scoopman for sharing their accounts. Of course now I just want my dealer to simply replace my junction box rather than waiting for it to fail.

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