21B69 – High Voltage Battery Module Unsealing – 2021 Ford Mustang Mach-E

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NHTSA ID Number: 10207906

Manufacturer Communication Number: 21B69

Summary

In all of the affected vehicles, incomplete sealing of certain high voltage battery modules may have occurred during the manufacturing process. An improperly sealed high voltage battery module could result in an electrolyte leak from the suspect battery module(s), resulting in an isolation fault or low battery module voltage condition, which may lead to an interruption of drivability.

 


PROGRAM TERMS 

This program will be in effect through February 1, 2023. There is no mileage limit for this program.

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Mustang Mach-E 2021 CUAUTITLAN August 10, 2021 through September 27, 2021

 

REASON FOR THIS PROGRAM

In all of the affected vehicles, incomplete sealing of certain high voltage battery modules may have occurred during the manufacturing process. An improperly sealed high voltage battery module could result in an electrolyte leak from the suspect battery module(s), resulting in an isolation fault or low battery module voltage condition, which may lead to an interruption of drivability.

 

SERVICE ACTION

Before delivering any new in-stock vehicles involved in this program, dealers are to inspect the high voltage battery modules and replace suspect modules per Attachment IV: Affected Battery Module List. If no Diagnostic Trouble Codes (DTC’s) are present, the battery modules can be replaced without any technical support. Should DTC’s (P0AA6, P0B24, and/or P0DE6) be present, dealers are to contact the technical assistance center (TAC) for diagnostic support to help determine an appropriate plan of action to service the vehicle. This service must be performed on all affected vehicles at no charge to the vehicle owner. 

NOTE: 

  • Each row of battery modules is called a battery array assembly. When ordering parts based on Attachment IV, both battery modules in a row must be replaced as an assembly.
  • Should DTC’s (P0AA6, P0B24, and/or P0DE6) be present, Roush technical support maybe required to aid in vehicle repair. Roush support is dependent on the plan of action provided by the technical assistance center (TAC).

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of February 14, 2022. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

 

SOLD VEHICLES

  • Owners of affected vehicles will be directed to dealers for repairs.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this service action.

 

OWNER REFUNDS 

Refunds are not approved for this program.

 

RENTAL VEHICLES

Dealers are pre-approved for up to 7 days for a comparable rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the day(s) the vehicle is at the dealership for part replacement. Prior approval for more than 7 rental day(s) is required from the SSSC via the SSSC Web Contact Site.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number Description Order Quantity Claim Quantity
W720404-S450eBay Bolt and Washer Assembly – (4 Per Pkg, up to 64 bolts required per repair. Dependent on location of affected battery modules) Up to 16 Pkgs Up to 64 Bolts
SEE BELOW FOR EXTENDED RANGE BATTERIES ONLY
LJ9Z-10D672-P Extended Range Battery Array Assembly Up to 2
LJ9Z-10D672-Q Extended Range Battery Array Assembly
LJ9Z-10D672-R Extended Range Battery Array Assembly Up to 1
LJ9Z-10D672-S Extended Range Battery Array Assembly
SEE BELOW FOR STANDARD RANGE BATTERIES ONLY
LJ9Z-10D672-T Standard Range Battery Array Assembly Up to 2
LJ9Z-10D672-U Standard Range Battery Array Assembly
LJ9Z-10D672-V Standard Range Battery Array Assembly Up to 1

 

Part Number Description Order Quantity Claim Quantity
W717859-S439eBay Bolts – (4 Per Pkg, 2 bolts required per repair) 1 Pkg 2 Bolts
TA-38 Battery Thermal Interface Material – (1 Per Pkg, up to 4 required per repair. Dependent on quantity of affected battery modules) Up to 4 Up to 4
VC-13DL-G Yellow Anti-Freeze 2 2

 


CERTAIN 2021 MODEL YEAR MUSTANG MACH-E VEHICLES — HIGH VOLTAGE BATTERY MODULE UNSEALING

 

SERVICE PROCEDURE

WARNING: Service of the high voltage system on this vehicle is restricted to qualified personnel. The required qualifications vary by region. Always observe local laws and legislative directives regarding electric vehicle service. Failure to follow this instruction may result in serious personal injury or death.

WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

WARNING: Never install the service disconnect plug when a high-voltage service cover is removed. Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.

WARNING: Disconnect the12 V battery before servicing the direct current to alternating current (DC-AC) inverter or alternating current (AC) powerpoint to prevent the risk of high voltage shock. Failure to follow this instruction may result in serious personal injury. WARNING: Any fluid or gel found within the high voltage battery tray is to be treated as battery acid and requires safety glasses and rubber gloves prior to clean up.

NOTE: It is recommended to discharge the vehicle battery down to 25%-30% before beginning any of the following work. Allow the vehicle to run with all the accessories running if at full charge. If unable to discharge the battery, each new module can take up to 7 hours each to charge, and up to 14 hours per array.

NOTE: With the high voltage battery removed, if the 12V battery is reconnected the vehicle will remain in Emergency Mode until the brake is pressed.

NOTE: If you become locked out of the vehicle, there is an access plug within the rear bumper.

NOTE: Make sure that the FDRS release level is at 30.5.3 or higher.

NOTE: If the FDRS cannot communicate with the BECM contact the technical assistance center (TAC) for diagnostic support.

1. Using FDRS or similar diagnostic scan tool, Check for DTC’s. Is DTC P0AA6, P0B24, and/or P0DE6 present?

YES – Contact the technical assistance center (TAC) for diagnostic support.

NO – Proceed to Step 2.

NOTE: Make sure that the FDRS release level is at 30.5.3 or higher.

2. Using FDRS, perform a Battery Energy Control Module (BECM) battery health check and record the BECM health tool generated target voltage code.

3. Remove the High Voltage Battery Cover. Please follow the Workshop Manual (WSM) procedures in Section 414-03A.

4. Reference Attachment IV: Affected Battery Module List and locate affected battery module(s). The battery module serial number is located on the sticker of each module. See Figure 1.

NOTE: For extended range batteries, the fifth row may need to be removed if all of the affected SN are not found with in the visible 5 rows and inspection of the fifth lower is needed. Please follow the WSM procedure in Section 414-03A.

 

NOTE: Each row of modules is called a battery array assembly. The modules in a row need to be replaced as a pair. See Figure 2.

 

5. Remove the array with the affected module(s). Please follow the WSM procedures in Section 414-03A.

 

6. Transfer the jumper harness from the inboard side of the module to the new module. See Figure 3.

NOTE: This jumper harness is found on all five rows except for the fifth upper on extended range.

 

7. Install the new battery array assembly. Please follow the WSM procedures in Section 414-03A.

8. Install the High Voltage Battery Cover. Please follow the WSM procedures in Section 414-03A.

9. Using FDRS, check and clear codes.

10. Charge the vehicle to 100 percent.

NOTE: Please verify if the vehicle is in One-Pedal Driving mode prior to the test drive. If the vehicle did not arrive with One-Pedal Driving mode activated prior to the test drive, turn off One-Pedal Driving before releasing the vehicle to the customer.

11. To activate One-Pedal Driving perform the following:

a. Touch the Mustang Mach-E icon in the upper-left corner of your touchscreen.

b. From the DRIVE MODE screen, slide the button to turn it on.

c. Use the brake to come to a complete stop if the vehicle does not slow down soon enough.

NOTE: Keep in mind that until you turn them off, Drive Modes and One-Pedal Driving will remain on each time you start the vehicle.

12. Perform a test drive of at least 20 miles (32 Km) in city driving conditions with One-Pedal Driving
activated to verify the repair.

  • City driving consisting of occasional acceleration and coast conditions. Safely but aggressively accelerate from 0-40 MPH (0-64 Kmh) and coast from 40-0 MPH (0-64 Kmh) with One-Pedal Driving activated to verify the repair.

NOTE: If the vehicle did not arrive with One-Pedal Driving mode activated prior to the test drive, turn off One-Pedal Driving before releasing the vehicle to the customer.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
FORD MACH-E 2021

 


1 Associated Document

Manufacturer Communications

Customer Satisfaction Program 21B69
February 1, 2022

https://www.nhtsa.gov/recalls?nhtsaId=10207906

MC-10207906-0001.pdf 1506.107KB

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