Investigation into Ford Mustang Mach-E recall

Home > Industry Analysis > Content

【Summary】The NHTSA is investigating Ford's response to a recall of almost 49,000 Mustang Mach-E vehicles due to a power failure risk. The recall was issued in June 2022 for a malfunction involving overheating of the high-voltage contactors, which can cause sudden power loss. Ford issued a software update to address the issue, but the NHTSA has received 12 consumer complaints about the solution, including instances where the problem persisted even after the update.

FutureCar Staff Aug 21, 2023 5:15 PM PT

Investigation into Ford Mustang Mach-E recall

The National Highway Traffic and Safety Administration (NHTSA) has initiated an inquiry into Ford's response to a recall that affected nearly 49,000 Mustang Mach-E vehicles last year, according to Automotive News. This recall, issued in June 2022, was prompted by a malfunction related to overheating of the electric SUV's high-voltage contactors. In the worst-case scenario, this issue could cause the EV to suddenly lose power while on the road, increasing the risk of a crash.

The problem often occurred after high-speed battery charging or repeated fast acceleration sessions. In response to the recall, Ford released an over-the-air (OTA) software update. This update was designed to reduce power if the contactors became too hot, with the aim of preventing sudden power loss and potential damage to the contacts. Additionally, the automaker halted deliveries of the Mach-E at dealerships until they received the software update. Ford also issued a service bulletin to replace the High Voltage Battery Junction Box in affected vehicles.

The NHTSA's Office of Defects Investigation has now received 12 consumer complaints regarding Ford's solution. As a result, the Office of Defects Investigation (ODI) has launched a Recall Query (RQ). These complaints allege failures of the high voltage battery main contactor in MY 2021-2022 Ford Mach-E vehicles that were part of Recall 22V-412 and had already been addressed before these incidents were reported. The remedy for this recall involved a software update for the Secondary On-Board Diagnostic Control Module (SOBDMC) to monitor contactor temperature and reduce battery power to prevent contactor damage. It also included a Battery Energy Control Module (BECM) software update to monitor contactor resistance and identify overheated contactors, reducing vehicle power to prevent further damage.

One customer complaint, dated August 19th, mentioned that they had to replace the High Voltage Battery Junction Box twice due to the same electrical system issue. Another complaint in February noted that the failure recurred even after receiving the software update.