FFE Transmission Failure

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On a ICE focus will have a torque surge when the transmission shifts into the next higher gear. Also the firering pulses from the engine will produce torque pulses that are transmitted through the entire drive line. While the FFE one speed gear box, has no shift points. The three phase motor produces constant torque through entire rotation of the motor shaft. This is a steady constant force being applied to the road.
 
Karlfev said:
New to this Forum. I have had my 2015 FFE for almost 4 months, let me reword that, I had my 2015 FFE for 3 months and the dealer service department has had it for almost a month. Long post, but guaranteed interesting read!

As I was preparing to pull into a parking lot, the car started to shudder similar to the way it feels when the ABS kicks in under hard braking, except I was driving slow but not breaking. As I entered the lot everything was fine and I was doing around 5 MPH about 100 yards into the lot. Suddenly it appeared as if the brakes locked up and it came to a screeching stop. The car left skidmarks approximately 18" long. The car would not move and the tires would not roll, ignition still on but nothing could make the car move. Tried turning it off and on, nothing! Turned it off and sat for 5 minutes and tried again, still nothing. Called Ford roadside assistance for a tow and sat back while I backed up traffic in the lot. After waiting an hour and 20 minutes, the tow truck arrived. When I told him the tires would not roll, he asked me to get in the car and he rocked it back and forth several times and we heard a loud snap and the car could suddenly move under it's own power. He loaded it onto his flatbed and we were off to the dealer. This happened on June 17th.

We got to the dealer and unloaded the car. I had previously showed them that the headliner was separating from the hatch area and they ordered a new one. They would install this then try to figure what was wrong with the locking up. About a week later, with a new headliner installed, they said they think it may be in the "gearbox" (they claimed that Ford does not call it a transmission) and that they would have a Ford FFE specialist check it out. Another week went by and I called back to have them say that they were still trying to figure things out. I decided to call the dealership GM and left a message. The next day a gentleman who announced himself as the service manager, called me. I told him of the problem and wondered why it was taking so long. He said they had been driving it and got it to lock up as well but were waiting on the Ford FFE specialist to tell them what to do. I mentioned to him that Ford has this wonderful app called "myFORDmobile" and that I can actually track where the car is on a map and it tells me the charge status and the number of miles driven. I also added that for the almost 3 weeks it had been in for service, that it had not recorded a mile having been driven, in fact because it is fairly accurate, I was able to see that it had been pretty much been sitting on their lot in the same place for most of the 3 weeks. He promised to find out the progress and keep me posted (and he has been calling me with regular updates since.)

on July 1st he left a message that they were going to take the FFE on a little 30 mile trip to see if it was still acting up. I called him back the next day and he said that they again had experienced the lock up and were just waiting for Ford. I mentioned that "...I guess you didn't get a chance to take it on that little trip..." his initial response was "...yes the technician took it out yesterday!" He paused and then said, "OH, you've got that app, don't you?" I answered "yes I do." Then he asked if it indicated that they did in fact take the trip and I replied "not according to the app." He said he would call me right back and he did, explaining that it was not necessary because it was locking up regularly now.

I waited till Monday the 6th and got in touch with Ford directly and opened a case number. The representative on the phone showed that the dealer had been in touch with them on the issue, but it did not start until after my call to the dealer GM. On Wednesday the 8th, I was informed that indeed there had been a catastrophic failure in the gearbox and pieces of metal were contaminating it. They ordered a new drive moter and gearbox and would try to get it done as soon as possible. They are thinking it may be done next week, about a month after this all happened.

BTW I had only put 1600 miles on the FFE when this all happened. Will let you all know what happens next week.
Sorry to hear about the dealer's incompetence & the FFE mechanical issue. Good for you for being on top of things via MFM to hold their feet to the fire. I hope that they will get the repair done correctly and perhaps you can get some compensation. Is your car leased or purchased? If it's leased, try to get Ford Corporate or the dealer to cover at least one of your payments since you've been unable to drive the car. If it's owned, ask for at least one loan payment or for a PremiumCARE ESP with $0 deductible as compensation.
 
hybridbear said:
Karlfev said:
New to this Forum. I have had my 2015 FFE for almost 4 months, let me reword that, I had my 2015 FFE for 3 months and the dealer service department has had it for almost a month. Long post, but guaranteed interesting read!

As I was preparing to pull into a parking lot, the car started to shudder similar to the way it feels when the ABS kicks in under hard braking, except I was driving slow but not breaking. As I entered the lot everything was fine and I was doing around 5 MPH about 100 yards into the lot. Suddenly it appeared as if the brakes locked up and it came to a screeching stop. The car left skidmarks approximately 18" long. The car would not move and the tires would not roll, ignition still on but nothing could make the car move. Tried turning it off and on, nothing! Turned it off and sat for 5 minutes and tried again, still nothing. Called Ford roadside assistance for a tow and sat back while I backed up traffic in the lot. After waiting an hour and 20 minutes, the tow truck arrived. When I told him the tires would not roll, he asked me to get in the car and he rocked it back and forth several times and we heard a loud snap and the car could suddenly move under it's own power. He loaded it onto his flatbed and we were off to the dealer. This happened on June 17th.

We got to the dealer and unloaded the car. I had previously showed them that the headliner was separating from the hatch area and they ordered a new one. They would install this then try to figure what was wrong with the locking up. About a week later, with a new headliner installed, they said they think it may be in the "gearbox" (they claimed that Ford does not call it a transmission) and that they would have a Ford FFE specialist check it out. Another week went by and I called back to have them say that they were still trying to figure things out. I decided to call the dealership GM and left a message. The next day a gentleman who announced himself as the service manager, called me. I told him of the problem and wondered why it was taking so long. He said they had been driving it and got it to lock up as well but were waiting on the Ford FFE specialist to tell them what to do. I mentioned to him that Ford has this wonderful app called "myFORDmobile" and that I can actually track where the car is on a map and it tells me the charge status and the number of miles driven. I also added that for the almost 3 weeks it had been in for service, that it had not recorded a mile having been driven, in fact because it is fairly accurate, I was able to see that it had been pretty much been sitting on their lot in the same place for most of the 3 weeks. He promised to find out the progress and keep me posted (and he has been calling me with regular updates since.)

on July 1st he left a message that they were going to take the FFE on a little 30 mile trip to see if it was still acting up. I called him back the next day and he said that they again had experienced the lock up and were just waiting for Ford. I mentioned that "...I guess you didn't get a chance to take it on that little trip..." his initial response was "...yes the technician took it out yesterday!" He paused and then said, "OH, you've got that app, don't you?" I answered "yes I do." Then he asked if it indicated that they did in fact take the trip and I replied "not according to the app." He said he would call me right back and he did, explaining that it was not necessary because it was locking up regularly now.

I waited till Monday the 6th and got in touch with Ford directly and opened a case number. The representative on the phone showed that the dealer had been in touch with them on the issue, but it did not start until after my call to the dealer GM. On Wednesday the 8th, I was informed that indeed there had been a catastrophic failure in the gearbox and pieces of metal were contaminating it. They ordered a new drive moter and gearbox and would try to get it done as soon as possible. They are thinking it may be done next week, about a month after this all happened.

BTW I had only put 1600 miles on the FFE when this all happened. Will let you all know what happens next week.
Sorry to hear about the dealer's incompetence & the FFE mechanical issue. Good for you for being on top of things via MFM to hold their feet to the fire. I hope that they will get the repair done correctly and perhaps you can get some compensation. Is your car leased or purchased? If it's leased, try to get Ford Corporate or the dealer to cover at least one of your payments since you've been unable to drive the car. If it's owned, ask for at least one loan payment or for a PremiumCARE ESP with $0 deductible as compensation.

Mine is still in the dealer lot after 7 weeks and they finally got around to order the "parts" which might be in next week. THEN they might get to install them so they can move the car inside (locked up due to broken motor mount bolt and CV joint). All I got from escalating to Ford was to be patient and that I should probably have gotten a rental all that time!

Been using a lemon law attorney but it is not likely that I will be able to get a new car; rather they might offer to refund my 2 monthly payments (over 550 each!) . I have NO faith that this will be the end of it as I had it scheduled a few days before the brake down for a non working AC (important to cool battery in summer). They are not planning to get to this until the car drives

Then I alerted them to the fact that the car is going into sleep mode (according App) and likely the 12V battery might be shot given the car have sat that long.
 
I have had my FEV back for over a week. Everything appears to be fixed and working like it should. I really missed the little "guy". I had been provided with a new Town & Country as a loaner (11 MPG...OUCH!).

Once I got the Service Manager and Ford involved, things were taken care of quickly. Both the dealer and Ford have had follow up calls with me to make sure everything is OK.

They had it for a total of one day short of 4 weeks. However, it really only took just under two weeks to get things fixed. BTW they found that the gearbox had a catastrophic failure and had spewed metal fragments through the gearbox and also damaged the electric motor. Both were replaced with new parts.

I am sorry to read that others have had more trouble getting their units fixed, but overall I must say I am satisfied....at least for now
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