Tag Archives: battery overheat

Ford Mustang Mach E Battery Contactor Could Overheat

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Certain 2021-2022 Ford Mustang Mach-E cars might face a power problem due to an overheated high voltage battery contactor, potentially leading to an increased risk of accidents.

In June 2022, Ford’s Field Review Committee (FRC) gave the green light to a Field Service Action (FSA) named 22S41, specifically designed to tackle concerns regarding the overheating of the high voltage battery main contactor in select 2021-2022 Mustang Mach-E vehicles. To fix this issue, dealers updated the software for the Secondary On-Board Diagnostic Control Module (SOBDMC) and the Battery Energy Control Module (BECM). The enhanced SOBDMC software keeps an eye on the contactor’s temperature and smartly reduces the battery’s power output to prevent further damage. Meanwhile, the upgraded BECM software checks the contactor’s resistance to identify any damage, then it generates a diagnostic trouble code (DTC) and lowers the vehicle’s power to avoid more harm.

At the time of approving this FSA, Ford’s Critical Concern Review Group (CCRG) and Electrical Propulsion Engineering (EPE) teams found the software updates for BECM and SOBDMC to be a suitable way to minimize the safety risks linked to power loss. The software update, by monitoring contactor resistance, warns customers if the resistance exceeds a certain limit. Alongside the warning, the software reduces power to prevent further contactor damage and the associated power loss risk. Even with the reduced power, customers can safely accelerate to highway speeds. This approach was also reviewed with the National Highway Traffic Safety Administration (NHTSA).

In June 2022, Ford Motor Company decided to issue a safety recall (NHTSA Recall 22V-412) for 48,924 model year 2021-2022 Ford Mustang Mach-E vehicles produced between May 27, 2020, and May 24, 2022. This recall was prompted by concerns about high voltage battery contactors overheating, primarily due to direct current (DC) fast-charging and repeated full-throttle pedal events. This overheating could lead to arcing or deformation of the electrical contact surfaces. If this occurs, the contactor could either remain open or get welded shut. An overheated contactor that opens while driving may lead to an immediate loss of power without re-engagement.

Following consumer complaints, the Office of Defects Investigation (ODI) initiated a Recall Query (RQ) for 2021-2022 Ford Mach-E vehicles included in Recall 22V-412. These vehicles had previously received a remedy involving a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to protect the contactor, as well as a Battery Energy Control Module (BECM) software update to monitor contactor resistance and reduce vehicle power in case of an overheated contactor.

To address this issue, dealers will replace the high voltage battery junction box. This recall is identified by Ford as 23S56, and the corresponding NHTSA campaign number is 22V-687. Vehicles included in this recall that were previously repaired under recall 22V-412 will need to have the new remedy completed.

Ford Mustang Mach-E Battery Problems Continue

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In the realm of electric vehicles (EVs), the 2021-2022 Ford Mustang Mach-E gained significant attention for its sleek design and promising performance. However, beneath its exterior allure, a complex challenge emerged that put the spotlight on battery-related issues. In June 2022, Ford Motor Company took steps to issue a safety recall (NHTSA Recall 22V-412) for a range of Mustang Mach-E vehicles, acknowledging battery problems that had the potential to impact both safety and performance.

2021-2022 Ford Mustang Mach-E Battery Recall

The safety recall was prompted by concerns related to high voltage battery main contactors. These components, integral to the functioning of the vehicle’s battery system, were at risk of overheating. The primary culprits behind this issue were the effects of direct current (DC) fast-charging and frequent aggressive acceleration events, which placed excessive stress on these contactors. Overheating, led to arcing or deformation of the electrical contact surfaces. Perhaps the most alarming consequence was the potential for a contactor to remain open, resulting in a sudden loss of motive power during driving. This raised significant safety concerns due to the increased risk of accidents resulting from unexpected power loss.

The Office of Defects Investigation

The recall was further complicated by the involvement of the Office of Defects Investigation (ODI). Following the initial recall (22V-412) involving approximately 48,924 vehicles, the ODI received a series of consumer complaints. These complaints highlighted incidents of high voltage battery main contactor failures even after the prescribed remedy had been implemented. This indicated that the initial software updates, aimed at temperature monitoring and power reduction, might not have fully resolved the underlying issues. This discrepancy called into question the effectiveness of the initial recall and the adequacy of its remedy.

Ford’s Response

In response to the ongoing concerns, Ford issued a Technical Service Bulletin TSB 23-2020 which focused on replacing the High Voltage Battery Junction Box (HVBJB) in the affected vehicles. The HVBJB is a crucial component that facilitates the connection between various parts of the high voltage battery system. Consumers who had experienced a loss of motive power post the initial recall were directed towards this bulletin. The bulletin aimed to ensure that the remedy for the contactor failures was comprehensive and addressed any lingering issues.

Addressing The Problem

The complexity of addressing battery-related problems in the 2021-2022 Ford Mustang Mach-E underscored the challenges of integrating advanced EV technology into mainstream vehicles. The initial recall and its subsequent developments shed light on the interplay between software solutions and hardware replacements. While software updates were intended to mitigate the risks, the need for a hardware replacement (HVBJB) became evident as consumer complaints persisted.

Conclusion

The battery problems encountered by the 2021-2022 Ford Mustang Mach-E vehicles served as a valuable lesson for both automakers and consumers in the evolving world of electric vehicles. The recall (22V-412), the Office of Defects Investigation’s involvement, and Ford’s multi-faceted response emphasized the importance of thorough and quick problem-solving in this rapidly advancing domain. As the automotive industry continues to innovate, experiences like these pave the way for safer and more reliable electric vehicles in the future.

2021-2022 Ford Mustang Mach-E Lemon Vehicle

If you find yourself grappling with persistent issues in your 2021-2022 Ford Mustang Mach-E vehicle, the California Lemon Law can offer you a potential lifeline. Designed to protect consumers from purchasing or leasing defective vehicles, this law provides a pathway to relief if your vehicle is deemed a “lemon.” If your Mustang Mach-E experiences substantial defects that impair its use, safety, or value, and these issues persist despite a reasonable number of repair attempts within the vehicle’s warranty period, you may be entitled to a replacement vehicle or a refund of the purchase price. The California Lemon Law serves as a crucial safeguard, empowering you to take decisive action to address your vehicle’s ongoing problems and helping you move forward with confidence.

2019-2024 Jaguar I-Pace Battery Could Overheat

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Certain 2019-2024 Jaguar I-PACE SUV electric vehicles are facing a critical issue that could pose a potential threat of vehicle fires due to excessive heat buildup inside the high-voltage battery. The Jaguar Product Safety and Compliance Committee (PSCC) identified this problem in February 2022 through the Jaguar Land Rover (JLR) critical concerns reporting process. As a result, Jaguar initiated a thorough investigation into the matter.

To address the issue, Jaguar collected the batteries from the affected vehicles and conducted meticulous inspections at their testing facilities. Subsequently, the batteries were sent back to the supplier for further and more detailed analysis. In addition, Jaguar acquired Diagnostic Over The Air (DOTA) data for comprehensive examination and evaluation.

According to the defect report, specific 2019-2024 Jaguar I-PACE SUV electric vehicles have experienced instances of thermal overload, which can manifest as smoke or fire. The overheating primarily occurs beneath the vehicle, where the high-voltage traction battery is located. While investigations are still ongoing, Jaguar has proactively decided to install software that will effectively monitor the battery’s status.

Owners of the affected vehicles will receive notifications regarding the issue. They can visit a dealer or opt for an over-the-air (OTA) update to have the battery energy control module software updated. This updated software will continuously monitor the operational status of the battery pack assembly, identifying conditions that may lead to a thermal overload. In order to ensure safety, the software will provide enhanced driver warnings regarding the battery’s condition. When a risk is detected, the charging capacity of the High Voltage battery will be limited to 75%. A warning message will alert the driver, accompanied by instructions in the Owner Guide, which will direct them to take their vehicle to a Jaguar retailer for diagnosis and, if necessary, repair. The retailer will conduct a thorough inspection and, if required, replace the affected battery module or pack.

Jaguar has assigned the identification number H441 to this recall, while the NHTSA campaign number is 23V-369.

Chevy Bolt Battery Problem Update

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General Motors is still rolling out new batteries for the troubled Chevy Bolt electric vehicle, albeit very slowly. We are hearing from clients and potential clients that dealerships are putting them on “wait lists” for the new battery but are not hearing again from the dealership. The dealerships give the owner no times table for getting their new battery as well. Obviously, this is very frustrating for consumers who are tired of figuring out ways to safely charge their EV. To date, we have only heard of the new batteries actually being installed in the 2017 – 2019 year models, but not for any 2020-2021 models. The good news is that once the battery has been installed, consumers seem to be happy with the new battery giving them a longer range than the original. More importantly, we have not heard of any problems associated with the new battery. This is good news for consumers.

With that said, we are still accepting Chevy Bolt cases, regardless of whether the new battery has been installed, and we continue to achieve favorable settlements with General Motors. Many of our settlements are for cash, allowing the consumer to receive compensation while being allowed to keep the vehicle.

Please call us at 1-888-395-3666 for more details about this problem.

Chevrolet Bolt EV

Here is a summary of the defect.
General Motors recalled all of their Chevrolet Bolt EVs because there is a manufacturing defect affecting the battery cell. The problem is aggravated when the battery is charged to a full or nearly full state after it has been substantially depleted. The battery could overheat and catch fire, causing damage to the vehicle and structures around it. As a temporary solution, GM asked owners to reprogram their hybrid propulsion control module to limit a full charge.

The safety recall from the NHTSA states the following:
As an interim remedy, dealers will reprogram the hybrid propulsion control module to limit full charge to 90%. Until this interim is completed, customers should enable either “Hilltop Reserve” (for 2017-2018 model year vehicles) or “Target Charge Level” (for 2019 model year vehicles) using their vehicle’s infotainment center. These two features will limit the vehicle’s state of charge to 90% until the HPCM2 software re-calibration is applied. If customers are unable to successfully make these changes or do not feel comfortable making these changes, they will be advised to not park their car in their garage or carport until after they have visited their dealer.

2021-2022 Ford Mustang Mach E High Voltage Battery Could Overheat

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Ford will be contacting the owners of certain 2021-2022 Mustang Mach E vehicles because the high voltage battery in their cars may overheat. The problem may lead to loss of power and could increase the chance of an accident.

Ford’s Critical Concern Review Group first became aware of the problem in April 2022, after hearing of an issue pertaining to the high voltage battery main contactor overheating in a Mustang Mach E. A review of warranty reports found approximately 286 warranty claims where the problem was an open or welded battery contactor. According to the defect report, it is possible that the high voltage battery main contactors may overheat, which can result in an open contactor or a welded condition.

Contactors that are welded shut while driving, will result in an illuminated powertrain malfunction warning light on the next drive cycle, along with a no-start condition.

Contactors that become open while driving, will result in a powertrain malfunction warning light, the vehicle will display “Stop Safely Now” on the instrument panel, and the vehicle will lose power.

In both cases, all 12V systems including power brakes and steering will remain functional.

Ford will correct the problem by installing a Secondary On-Board Diagnostic Control Module (SOBDMC) and updating the Battery Energy Control Module (BECM) software. Ford is expected to begin Over-The-Air (OTA) updates for the SOBDMC and BECM software in July 2022. Owners will also have the option to take their vehicle to a Ford or Lincoln dealer to have the software update completed.

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. The updated BECM software (NJ98-14C197-AE, NJ98-14C197-BD) will monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage.

Ford’s number for this recall is 22S41 and the NHTSA campaign number is 22V-412.