The Black Mace has two triggers - one happens immediately after a wound is caused, so if you caused 4 wounds, you'd allocate the first, the 'Surge would get an Invulnerable save (if it has one?) and Feel No Pain (GMC?) before taking the first Toughness test. You'd repeat the process for the remaining three, taking a T test after each unsaved wound.
The second trigger happens at the end of the phase, and doesn't affect a model that has already taken a wound from the mace that turn, and only happens once per turn regardless of how many wounds are caused.
In the challenge question, if there are no non-challenge models for the rest of the unit to attack, they will attack the character in the challenge (this is a change from 6th edition, where they were basically reduced to cheerleaders).
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