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Ford’s Mustang Mach-E Rally ready for off-road challenges

Ford Motor Company has announced the development and testing of the Mustang Mach-E Rally, a rally-inspired version of the Mustang Mach-E. This project, which began as an idea in 2022, has now culminated in a vehicle that combines design and engineering to handle rallycross conditions.

Product planners Peter Schultz and Craig Migliori initiated the project by modifying a Mach-E GT with off-road tires and taking it to Ford’s Michigan Proving Grounds. The testing confirmed the vehicle’s potential for rallycross, leading to the development of the Mach-E Rally with enhanced capabilities and features.

The Mach-E Rally includes a 1-inch lift from the standard Mach-E GT suspension height, rallycross-tuned shocks and springs, and Michelin CrossClimate2 tires on 19-inch wheels. The vehicle also has underbody shielding, a unique front splitter, a rear spoiler, and rally-inspired fog lights. These modifications aim to provide the vehicle with both aesthetic appeal and functional performance on rough terrain.

Ford’s off-road attributes engineer Chris Berchin and vehicle engineering supervisor Jay Kistler led the rigorous testing of the Mach-E Rally. The testing included a new 500-mile torture test designed to simulate ten years of rallycross racing. This involved driving in various weather conditions and on different dirt surfaces to ensure the vehicle’s performance and durability.

The team also developed a rallycross testing course at Ford’s Michigan Proving Grounds, ensuring it accurately reflected real rallycross environments. The course was designed using computer-aided engineering to map out elevation, speeds, and other factors. This in-house development helped maintain project secrecy and control costs.

The Mustang Mach-E Rally features several technical enhancements, including powertrain calibration, traction control, and MagneRide suspension, all tuned for dirt-track performance. Ford also introduced a new RallySport drive mode, which optimizes the vehicle for dirt-track driving by allowing for added yaw, linear throttle response, and more aggressive damping.

This project has been recognized with a Vehicle Engineering Validation award from Ford, celebrating the successful in-house design and realization of the Mustang Mach-E Rally. The vehicle, which started as a concept in 2022, is now ready for customer orders and will soon be available for rallycross enthusiasts.

Written by EV Pulse Staff

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