In early 2022, a rally-inspired version of the Mustang Mach-E began as an idea among engineers, sparked by a simple question: “Can we make a rally-inspired version of the Mustang Mach-E?”
Product planners Peter Schultz and Craig Migliori took up the challenge by modifying a Mach-E GT with new wheels and off-road tires, testing its capabilities at Ford’s Michigan Proving Grounds. Their experiment proved successful, leading to the development of the Mustang Mach-E Rally.
The team aimed to create a vehicle that not only looked the part but also possessed true rallycross capabilities. They raised the Mach-E Rally by one inch from the standard Mach-E GT suspension height, incorporating rallycross-tuned shocks and springs. The SUV is equipped with 19in gloss-white wheels wrapped in Michelin CrossClimate2 tires for enhanced traction on loose surfaces.
Underbody shielding was also added to protect the vehicle during off-road driving.
For a high-performance look, the Mach-E Rally features unique accents, including upper and lower body moldings, a special front splitter, a rear spoiler, a black painted steel roof and built-in rally-inspired fog lights.
The Mustang Mach-E Rally includes modifications such as powertrain calibration, traction control and MagneRide suspension tuned for dirt-track performance. The raised suspension enhances the vehicle’s capability on dirt roads.
Ford’s new RallySport drive mode has also been integrated to improve the vehicle for dirt-track driving by allowing for increased yaw for bigger slides, a linear throttle response for better control and more aggressive damping for handling loose corners.
Testing and development
To ensure the vehicle could withstand intense rallycross conditions, Ford off-road attributes engineer Chris Berchin and vehicle engineering supervisor Jay Kistler conducted rigorous testing. This included an 800km torture test at Ford’s Michigan Proving Grounds, simulating 10 years of rallycross racing. The testing involved various weather scenarios and dirt surfaces to reflect typical rallycross conditions.
“We tested in numerous different weather scenarios and temperatures with conditions ranging from muddy to dry – typical of what rallycross competitors might face,” Berchin said. “Likewise, the surface is dirt of varying composition, allowing for different traction scenarios.”
Before the creation of the dedicated rallycross testing course at Ford’s Michigan Proving Grounds, engineers attended rallycross events and consulted with drivers to design a course that accurately mirrored real rallycross environments. The course was mapped using computer-aided engineering (CAE) analysis to ensure precise replication of elevation changes, speeds and timing.
The Mustang Mach-E Rally is due to become available to customers soon.
