The creation of the Mustang Mach-E® Rally began with a simple question posed in an engineering breakroom: “Can we make a rally-inspired version of the Mustang Mach-E?” This question set the stage for a groundbreaking project led by Ford’s product planners, Peter Schultz and Craig Migliori. Their initial experiment involved retrofitting a standard Mach-E GT with off-road wheels and tires and testing its capabilities at the Ford Michigan Proving Grounds. The results were unequivocally positive, affirming their vision for a rally-ready vehicle.
Engineering for the Rally Track
Understanding that the Mach-E Rally needed to live up to its nameplate in both appearance and functionality, the team embarked on a series of enhancements. These modifications included a 1-inch lift over the standard Mach-E GT, RallyCross-tuned shocks and springs, and robust Michelin® CrossClimate2 tires. The vehicle was also equipped with protective underbody shielding and styled with distinctive rally-inspired features such as a black painted steel roof, aggressive moldings, a front splitter, a rear spoiler, and integrated fog lights.
Testing and Validation
To convincingly demonstrate the vehicle’s rally prowess, Ford’s engineering team, led by off-road attributes engineer Chris Berchin and vehicle engineering supervisor Jay Kistler, conducted rigorous testing. This included a comprehensive 500-mile torture test designed to simulate a decade of monthly rallycross races. The test track, specifically constructed for this purpose, mimicked real-world rallycross conditions, incorporating varied weather scenarios and dirt compositions to test traction and handling.
Developing the RallyCross Course
The transformation of a grassy field at Ford’s Michigan Proving Grounds into a full-fledged rallycross testing course was pivotal. Prior to construction, the team engaged with rallycross events and drivers to ensure authenticity. Through detailed computer-aided engineering analysis, they meticulously planned every turn and elevation of the course, validating it with advanced sensors and measuring equipment to capture the true essence of rallycross racing.
Innovations and Achievements
The project’s in-house approach not only streamlined costs and development time but also maintained the secrecy of the Mustang Mach-E Rally’s development. This strategic initiative earned the team the Vehicle Engineering Validation award from Ford, celebrating their innovative and self-contained project management. Furthermore, the vehicle was equipped with a specialized RallySport drive mode, enhancing performance on dirt tracks with features like adjusted yaw control, linear throttle responses, and aggressive damping.
The Mustang Mach-E Rally, birthed from a moment of curiosity, has evolved into a robust rally-inspired vehicle ready to tackle the dirt tracks. With its advanced engineering and dedicated testing, the Mach-E Rally is poised to bring thrilling rally performance to customers and enthusiasts alike, marking a new chapter in Ford’s legacy of innovation and adventure on the rally scene.
