Mustang Mach-E Rally developed for rallycross conditions

Ford Motor Company has unveiled the Mustang Mach-E Rally, an off-road, rally-inspired variant of the Mustang Mach-E. The development of this vehicle began in 2022, evolving from an initial concept into a fully engineered product designed to handle rallycross conditions.

The project started when product planners Peter Schultz and Craig Migliori modified a Mach-E GT by adding off-road tires and testing it at Ford’s Michigan Proving Grounds. The positive results from these initial tests led to the creation of the Mach-E Rally, which features several enhancements for improved performance in rallycross environments.

Key modifications to the Mach-E Rally include a 1-inch lift from the standard Mach-E GT suspension height, rallycross-tuned shocks and springs, and Michelin CrossClimate2 tires mounted on 19-inch wheels. Additional features comprise underbody shielding, a distinctive front splitter, a rear spoiler, and rally-inspired fog lights, aimed at enhancing both the vehicle’s aesthetics and functionality on rugged terrain.

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

A rallycross testing course was developed at Ford’s Michigan Proving Grounds, using computer-aided engineering to accurately simulate real rallycross environments. This approach allowed Ford to maintain project secrecy and control costs effectively.

The Mustang Mach-E Rally features technical enhancements such as powertrain calibration, traction control, and MagneRide suspension, all tuned for dirt-track performance. It also introduces a new RallySport drive mode, which optimizes the vehicle for off-road driving with improved yaw control, linear throttle response, and more aggressive damping.

The Mustang Mach-E Rally has received a Vehicle Engineering Validation award from Ford, recognizing the successful in-house design and development of the vehicle. It is now ready for customer orders and will soon be available to rallycross enthusiasts.