Unleashing Innovation – The Journey of the Mustang Mach-E® Rally

A Ford Mustang Mach-E doing early testing on a rally course for the Mach-E Rally.

The development of the Mustang Mach-E® Rally exemplifies how a simple question can evolve into a groundbreaking automotive project. This blog post takes a closer look at the conception, challenges, and triumphs in the making of this rally-inspired vehicle. 

From Concept to Reality

It all started with a straightforward question in an early morning meeting in 2022: “Can we make a rally-inspired version of the Mustang Mach-E?” This question, posed to Ford product planners Peter Schultz and Craig Migliori, sparked a flurry of innovation and experimentation. 

Using a handed-down Mach-E GT, the team equipped it with robust wheels and off-road tires and took it to Ford’s Michigan Proving Grounds. The result? A resounding confirmation that not only could it be done, but it could excel. The vehicle not only had to look the part but also needed genuine rallycross capabilities. 

Ford engineers around a Mustang Mach-E doing early tests for the Mach-E Rally.

Design and Engineering Marvel

The Mustang Mach-E® Rally was designed with performance in mind. It features a 1-inch lift from the standard Mustang Mach-E GT suspension, RallyCross-tuned shocks, and springs ideal for navigating rough terrain. The vehicle sports gloss-white 19-inch wheels encased in Michelin® CrossClimate2 tires, providing exceptional traction and durability for off-road conditions. Added underbody shielding protects against dirt and debris typical in rallycross driving. 

Visual enhancements were equally strategic, incorporating contrasting accents, aggressive body moldings, a front splitter, a rear spoiler, and rally-inspired fog lights, all under a sleek black painted steel roof. 

A professional driver doing early testing for the Mustang Mach-E Rally.

Testing and Validation

Key to the Mach-E Rally’s development was rigorous testing. Chris Berchin, Ford’s off-road attributes engineer, and Jay Kistler, vehicle engineering supervisor, spearheaded a 500-mile torture test designed to simulate 10 years of rallycross racing. This intensive testing regimen ensured the SUV could handle various terrains and weather conditions, typical of what professional rallycross drivers face. 

A Mustang Mach-E doing early testing on a rally course for the Mach-E Rally.

Building the Rallycross Testing Course

An unused field at the Ford’s Michigan Proving Grounds was transformed into a state-of-the-art rallycross testing course. Prior to construction, the team gained insights by attending rallycross events and consulting with professional drivers to ensure the course authentically mimicked real racing conditions. 

The course was meticulously planned with computer-aided engineering tools to analyze expected speeds, timing, and elevation changes. This technological approach allowed for precise adjustments to the course layout, ensuring it met professional standards. 

Innovations and Achievements

The modifications to the existing Mustang Mach-E® included adjustments to the powertrain, traction control, and MagneRide® suspension to enhance dirt-track and rallycross performance. The introduction of Ford’s RallySport drive mode tailored the SUV for dirt tracks, improving handling and control without compromising the vehicle’s on-road capabilities. 

These efforts culminated in the Mustang Mach-E® Rally receiving the Vehicle Engineering Validation award from Ford, celebrating the successful in-house design and development. 

The new Ford Mustang Mach-E Rally in a beautiful, wooded setting.

What began as a simple query about the feasibility of a rally version of the Mustang Mach-E® has transformed into a fully-realized, innovative project ready to hit the dirt tracks and soon, customer driveways. The Mustang Mach-E® Rally not only pushes the boundaries of automotive design and engineering but also showcases Ford’s commitment to blending passion with technological advancement. 



Find Your Next Vehicle

search by model, color, options, or anything else...