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Mustang Mach-E Rally: Rigorous Testing And Development Insights
What began as a casual conversation in an engineering breakroom has evolved into the Mustang Mach-E® Rally, a testament to the fusion of passion and engineering. In early 2022, product planners Peter Schultz and Craig Migliori pondered whether a rally-inspired version of the Mustang Mach-E could be created. They tested a modified Mach-E GT at Ford’s Michigan Proving Grounds, and the results were promising.
The team aimed to ensure the Mach-E Rally not only looked the part but also performed exceptionally in rallycross conditions. The vehicle features a 1-inch lift from the standard Mustang Mach-E GT suspension height, with RallyCross-tuned shocks and springs for handling rough terrain. Gloss-white 19-inch wheels wrapped in Michelin® CrossClimate2 tires provide traction on loose surfaces, while underbody shielding protects against dirt and grime.
To enhance its performance profile, the team added unique accents such as upper and lower body moldings, a front splitter, a rear spoiler, a black painted steel roof, and built-in rally-inspired fog lights. Despite these modifications, proving the vehicle's rallycross capabilities required rigorous testing.
Ford off-road attributes engineer Chris Berchin and vehicle engineering supervisor Jay Kistler led the drive testing. They conducted a 500-mile torture test at Ford’s Michigan Proving Grounds, simulating ten years of monthly rallycross racing. The tests included various weather conditions and temperatures, reflecting typical rallycross environments.
Chris Berchin explained, "We tested in numerous different weather scenarios and temperatures with conditions ranging from muddy to dry – typical of what rallycross competitors might face." The surface varied in composition, providing different traction scenarios essential for comprehensive testing.
The team transformed an unused field at Ford’s Michigan Proving Grounds into a rallycross testing course. They attended rallycross events and interviewed drivers to ensure authenticity. A full computer-aided engineering (CAE) analysis was conducted to map elevation, expected speeds, timing, and more.
This in-house development approach helped keep costs down and maintained secrecy around the project. The team received a Vehicle Engineering Validation award from Ford for their successful project. The Mustang Mach-E Rally modifications include powertrain calibration, traction control, and MagneRide® suspension tuned for dirt-track capability.
The raised suspension enhances performance on dirt roads. These changes contribute to Ford’s RallySport drive mode, which optimises the vehicle for dirt roads without compromising on-road behaviour. The RallySport drive mode allows for added yaw for bigger slides, linear throttle response for better control, and aggressive damping for improved handling in loose corners.
The Mustang Mach-E Rally will soon be available to customers and ready for dirt track adventures.
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