Jun 11
Overheating reported by text, mid-drive
Callback requested. System confirms message sent to service team.
Jun 12 AM
No callback overnight
Owner arrives next morning; no record the text was ever actioned.
Jun 12
Recall update + multi-point inspection
Battery noted "in good condition." Vehicle released — one day before 419°F.
Jun 13
FDRS: EXTERIOR_TEMP 419°F, GCLTEMP 399°F
Refrigerant valves A & B: "no fault detected, output commanded off." No lamp, no DTC, no shutdown.
Jun 13
Truck left with dealer; owner flies home
Verbal assurance from Service Manager that Ford would cover the flight.
Jun 20
Letter mailed — CEO
Certified. Names the 419°F failure directly.
Jun 20
Letter mailed — President, Ford Model e
Certified, same content.
Jun 20
Letter mailed — President, Ford Blue
Certified, same content.
Jun 20
Letter mailed — Customer Relations
Certified, same content.
Jun 26
USPS confirms all 4 delivered
None of the 3 named executives ever reply.
Jul 1
Charging: 10%→63%, 68 kWh/63 min, 65 kW avg
~50% of the 110–130 kW expected below 80%.
Jul 8
Overheating reproduced, gauge photographed
Deliberately recreated by Service Manager. Yellow zone, no warning triggered.
Jul 8
Charging: 41%→70%, 39 kWh/48 min, 49 kW avg
Slowest session on record — same day as the reproduction above.
Jul 13
"Unable to replicate" — 5 days after it was
Direct contradiction of the July 8 reproduction and photo.
Jul 15
Preservation demand — module software
Requires capture before any reflash occurs.
Jul 15
Preservation demand — diagnostic history
Full DTC history, current and historical, with freeze-frame data.
Jul 15
Preservation demand — battery state of health
Cell-level data specifically requested.
Jul 15
Preservation demand — all removed parts
None honored in writing to date.
Jul 21
"Gearing up for closure" vs. dealer: not ready
Same-day contradiction between Ford rep and dealer.
Jul 22
Repurchase request filed — warranty grounds
Written warranty, PremiumCARE, Magnuson-Moss, product liability. No lemon law claim made.
Jul 22
Attorney packet assembled, held in reserve
Drafted at attorney's suggestion; deliberately not sent.
Jul 28
TSB 23-2126 performed
Addresses an air-dam message the truck never displayed.
Jul 28
Overheating recurs — faster than before
Same day as the TSB "fix."
Jul 29
Overheating reproduced a 3rd time
Photographed again, gauge in yellow.
Jul 30
Charging: 77%→90%, 19 kW avg
Still below spec, but 3x better than the Aug 7 session that follows.
Aug 1
Buyback denied — 1st time, lemon law cited
Relief under that law was never requested.
Aug 1
Charge port replaced, no findings shared
No diagnosis given; removed part's test results never provided.
Aug 3, 2:31p
Owner requests RAV case number, agent, date
Reply: RAV team "NOT customer facing" — no number given.
Aug 3
Coupler hits 419°F again; real DTCs found
Separate FDRS session: BC_COUPL_TEMP_C at 419°F, ambient 93–100°F. Stored DTCs found: "Active Air Dam Stuck" and "Battery Charger Coupler Temperature 'D' Too High" — first confirmed trouble codes in this case. No driver warning either.
Aug 4, 9:42a
4-point demand: rental, expenses, next steps, cell proof
Rep cites a 3-hr meeting, says she'll loop in an internal "task force" team.
Aug 4
Receipts sent (Hays, KS + rental)
Rep: "Received," filing a new buyback request.
Aug 4
Owner: "did you get everything from Whitey?"
Rep confirms yes, reiterates new BB request in progress.
Aug 4
Owner: "has it been submitted?"
Rep: "attaching documents as we speak."
Aug 4
Owner: "did the data include battery condition?"
Rep: no — "technical information will not be provided to me in print."
Aug 4
Owner: "how does the port affect cooling?"
Rep: port being replaced tomorrow, then drive/charge tests.
Aug 4
Owner presses again — no mechanism given
Rep clarifies: engineer says port causes overheat only during fast-charge; not a cooling-system issue.
Aug 5, 5:44p
Owner flags 50% charge / 93-mile range
Well below what that state of charge should deliver.
Aug 6 AM
Rep: will call Service Manager, then owner
Noon "task force" meeting also referenced.
Aug 6, 5:08p
"Denied again for the same reason"
— "outside of the time period for filing," per rep, in writing.
Aug 6, 6:47p
Owner demands a "finish line" date
Invokes Magnuson-Moss and product liability; "can't" no longer accepted.
Aug 7, 12:36p
"Battery did not overheat" post-repair
Port called unrelated to cooling; warning system said unaffected.
Aug 7, 2:45p
Owner debunks "plugged in too long," demands criteria
Ford's own manual says keep it plugged in. Asks who decides, and by what standard, today.
Aug 7, 3:25p
Session terminates after 2 min (42%)
Normal ~120 kW rate, then cuts off. App: "Charging error."
Aug 7, 4:04p
2nd session terminates after 1 min (44%)
Same failure pattern repeats.
Aug 7, 2:04p
"Denied a second time" — reconfirmed
Rep raises returning the truck unfixed if assistance ends here.
Aug 7, 3:14p
Owner: "not an answer"
Rejects returning the truck unfixed as a resolution.
Aug 7, 6:17p
3rd session stuck at 6.4 kW (82%)
~1/10th of Ford's own published expected rate.
Aug 7, 6:23p
Still stuck: 6.6 kW (83%), 2+ hrs total
Sustained low rate for over two hours.
Aug 7, 3:26p
Rental reimbursement denied
Called "not feeling secure with the vehicle," not a response to a documented defect.
Aug 8
Formal notice sent to Ford's Office of General Counsel
Full letter — incident history, Ford's handling, outstanding questions, repurchase request — sent via UPS and email, with a 3-business-day response request. First direct contact with Ford's legal department in this case.