Safety Recall 22S41 - 2021-2022 Mach E - HVBJB Recall [high voltage battery main contactors may overheat]

[Secret Sauce]

I know for a fact there is new hardware that is being produced. I also know for a fact the software isn't ready from what I've been told by the powers that be. So that's where we are now. Doesn't mean the person who told me this is right, but I do know for a validated fact there is new hardware...I just don't know what it is going into...if anything other than broken cars.

You know a guy who knows a guy?

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[EADiamondHomes]

I took mine in for the windshield recall and they did the module update for this at the same time, nice surprise.
Also, on another note, they did not do the Blue Cruise update, as scheduled to do, because several others in at the same time were done and the vehicle was left in operable so apparently there is some corruption in the software they were sent. So glad they didn’t do mine!

 

[H.Bergeron]

Thanks for posting this. Most helpful comment so far. It makes sense for Ford to use software to prevent drivers from getting stranded.

It answers some questions but also provokes others:

• Why does this effect nearly all and only cars made in Mexico?
  • Are they using different hardware in Mexico?
  • Why would the same hardware installed elsewhere not have similar problems?
  • Why would Ford different parts for different manufacturing locations?
  • Are they using different software?(seems highly unlikely)
  • Or is this due to installation variations of the same part by workers in Mexico?
• If all cars not made in Mexico are good, is Ford going to begin using the same hardware (if different) from elsewhere in Mexico going forward?
• If this is related to installation/ manufacturing, wouldn’t it be an easy fix for dealers to tighten up loose contacts or fix whatever else is wrong?
• Is Ford just planning on addressing this issue reactively for people who have a problem identified by the software patch?
  

It seems like a software bandaid is good insofar as it keeps people from getting stranded. But if there is an underlying hardware issue, Ford should give owners the option to have it repaired proactively. Some owners may feel “ticking time bomb” anxiety.

The recall has now been posted to the NHTSA website with lots of details.

They confirm it's only a software update:



And every listed component (all 50 of them) in the attached PDF is software - no physical parts mentioned.

The document also confirms updates will be available in July (not just the vague "Q3" we heard yesterday).

It also describes what the software will do:



It sounds to me like this will reduce power only when a dangerous situation with the contactors has been detected - I imagine when you've got the combination of DCFC and flooring the pedal that Ford mentioned yesterday.

On the bottom of page 10, it says the problem was corrected in production simply by introducing new software on May 25, 2022. The speculation about different hardware being used in post-May 25 builds seems to have been unfounded:



Other interesting historical details:



* VOQ = Vehicle Owner Questionnaire

 

[BMT1071]

Thanks for posting this. Most helpful comment so far. It makes sense for Ford to use software to prevent drivers from getting stranded.

It answers some questions but also provokes others:

• Why does this effect nearly all and only cars made in Mexico?
  • Are they using different hardware in Mexico?
  • Why would the same hardware installed elsewhere not have similar problems?
  • Why would Ford different parts for different manufacturing locations?
  • Are they using different software?(seems highly unlikely)
  • Or is this due to installation variations of the same part by workers in Mexico?
• If all cars not made in Mexico are good, is Ford going to begin using the same hardware (if different) from elsewhere in Mexico going forward?
• If this is related to installation/ manufacturing, wouldn’t it be an easy fix for dealers to tighten up loose contacts or fix whatever else is wrong?
• Is Ford just planning on addressing this issue reactively for people who have a problem identified by the software patch?

It seems like a software bandaid is good insofar as it keeps people from getting stranded. But if there is an underlying hardware issue, Ford should give owners the option to have it repaired proactively. Some owners may feel “ticking time bomb” anxiety.

Aside from MMEs built and delivered in China, all of them are made at the same plant in Mexico.

 

[Neil4Real]

I took mine in for the windshield recall and they did the module update for this at the same time, nice surprise.
Also, on another note, they did not do the Blue Cruise update, as scheduled to do, because several others in at the same time were done and the vehicle was left in operable so apparently there is some corruption in the software they were sent. So glad they didn’t do mine!

Not possible.

 

[Electric Goat]

In 1998 I bought a Mustang Cobra and when I took it in, for a problem I can't remember, the tech told me I was driving it too hard. So I asked him if I take it to Dearborn to drive it on the track (you got an invitation from Ford if you had a SVT vehicle back then) should I go slowly around so I don't hurt it? The point of a performance vehicle is to drive it not baby it. Worse part is I love this freaking car.

Exactly. Why even call it a performance model if it can't even drive for extended periods of time on public roads. Driving it on a race track is significantly more brutal. But saying that we can go WOT on occasion on the street? Come on, man!

 

[H.Bergeron]

Aside from MMEs built and delivered in China, all of them are made at the same plant in Mexico.

Why are the cars made in China unaffected? Or are they and neither China nor Ford cares? Or do we just not know?

 

[buzznwood]

Why are the cars made in China unaffected? Or are they and neither China nor Ford cares? Or do we just not know?

The vehicles made in china will be using different parts suppliers where it will make financial sense for Ford to do so. As a result there can be a lot of regional differences between models just from a parts perspective.

 

[H.Bergeron]

So this could even be an issue of variability from part to part built by the supplier.

The vehicles made in china will be using different parts suppliers where it will make financial sense for Ford to do so. As a result there can be a lot of regional differences between models just from a parts perspective.

 

[breeves002]

You know a guy who knows a guy?

Everyone knows a guy.

 

[yngwenli]

I was watching that "Ending Contactor Destruction" video in the thread which was pumping 245 Amps through/to a Contactor.

I suppose if that MME part never actually needs 245 Amps to work (or whatever the MME uses), a SW fix could lower that if say, 20 or 50 amps is just as good and any more has no benefit.

The truth will be people testing after this SW fix.

 

[cbcasas]

So if I’m already running SOBDMC version -BBG can I assume I have the (partial) fix to this?


The updated SOBDMC software (LJ98-14G069-AXG. LJ98-14G069-AZG, LJ98-14G069-BBG. LJ98-14G069-BDG) will monitor contactor
temperature and intelligently reduce battery power to prevent damage to
the contactor.

 

[Fixbear]

So if I’m already running SOBDMC version -BBG can I assume I have the (partial) fix to this?


The updated SOBDMC software (LJ98-14G069-AXG. LJ98-14G069-AZG, LJ98-14G069-BBG. LJ98-14G069-BDG) will monitor contactor
temperature and intelligently reduce battery power to prevent damage to
the contactor.

I was watching that "Ending Contactor Destruction" video in the thread which was pumping 245 Amps through/to a Contactor.

I suppose if that MME part never actually needs 245 Amps to work (or whatever the MME uses), a SW fix could lower that if say, 20 or 50 amps is just as good and any more has no benefit.

The truth will be people testing after this SW fix.

If you use a level 3 fast charger, some are capable of 150kw. Not knowing what the battery voltage is, it can easily be over that. A 800 volt battery would be able to take 185 amps max. But a lower pack can be over 300 amps.

 

[FLmac]

Thanks FLMac. Will try to Chill and praying my 5/30 week build moves from "in production" to built soon. I contacted my dealer to see if they can see any more information. I have a buyer for my 2017 Volt right now but don't want to cut it loose without a solid feel that I will take delivery before end of October. I have a 2015 Mustang GT but its not made for Wisconsin winters!

DO NOT SELL YOUR CURRENT CAR unless you are fine not having the new car for an extended period of time! I almost made this mistake on Monday afternoon and 2 hours later my car that should be at the dealer next week is now on recall. I’ve seen so many posts about people selling their car early because their new one was almost done and then something happens.

 

[buzznwood]

So this could even be an issue of variability from part to part built by the supplier.

From the Ford FAQ

Q. What is the cause of the issue?
A. The design and part-to-part variation of the high voltage battery main relay switch is not robust to the heat generated during DC fast charging and multiple wide open pedal events.

If you look at the that you will see part to part variance, but most parts will typically have a manufacturing variance and parts suppliers will state the variance so manufacture can then see if that variance fits within an acceptable tolerance. The key words are NOT ROBUST, a part has been chosen and used that is not up to the task at hand.

This part should have failed during regular testing procedures and never got anywhere near a production vehicle, that is has means either Fords testing procedures are hopeless or the part did initially pass without issue and as can happen all the time in manufacturing revisions to it have been made by the supplier but the revised part was not rested which is just as bad.

PR will do its best to down play but from a Ford engineering perspective there can be no excuses for making such a cock up.

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