Ford Mustang Mach-E Recall Investigation Launched by NHTSA, After Battery Failures Reported in Repaired Vehicles

Federal safety officials are investigating problems with nearly 65,000 Ford Mustang Mach-E vehicles, which were previously recalled due to battery failures, but appear to still be experiencing issues even after repairs were supposedly made.

The National Highway Traffic Safety Administration (NHTSA) announced the Ford Mustang Mach-E recall repair investigation on August 17, indicating that the agency has become aware of at least a dozen consumer complaints involving their vehicles unexpectedly losing motive power after receiving Ford’s recall repairs.

The agency warns the vehicles can suddenly lose power and may not re-engage, increasing the risk of the occupants sustaining serious injuries in an auto accident.

Officials indicate that the electric vehicles appear to have received Ford’s software updates and replacement parts after the recall was announced. However, they are now investigating whether the repairs were adequate, as consumers continue to report issues with their vehicles after receiving repair.

Ford Mustang Mach-E Recall

Ford issued the Mustang Mach-E recall in June 2022, affecting about 48,924 model year 2021 through 2022 vehicles manufactured from May 27, 2020 until May 24, 2022. The recall followed hundreds of warranty claims involving overheated high voltage battery main contactors, which caused the parts to remain open or weld shut.

The NHTSA warned that the battery problems may result in immediate loss of power, which could lead to a loss of control and an auto accident.

To remedy the issue, Ford provided software updates to the vehicle’s diagnostic control and battery energy control modules, which were intended to monitor the contactor’s temperature, identify resistance or overheating, and to reduce the power generated by the battery to avoid further damage to the components.

Ford introduced the updated software into new Mustang Mach-E vehicles beginning on May 25, 2022.

Following the recall announcement, the automaker released a technical service bulletin for the recalled vehicles to receive a replacement high voltage battery junction box.

Ford Mustang Mach-E Recall Repair Problems

Following the recall repairs, Mustang Mach-E owners continued to experience battery failures, which resulted in loss of power while they were driving. To date, the agency has become aware of at least 12 incidents involving drivers experiencing a sudden reduction or complete loss of power while operating the vehicle.

As part of its investigation, the NHTSA will assess the recall repairs provided by Ford to determine if they were adequate to address the issue, or if another remedy should be implemented.

The agency’s investigation impacts approximately 64,727 model year 2021 through 2022 Ford Mustang Mach-E vehicles, and includes the vehicles that were subject to the recall, as well as the vehicles produced with the updated software beginning on May 25, 2022, following the recall.

For more information, owners may contact the NHTSA’s vehicle safety hotline by phone at 1-888-327-4236 (TTY 1-800-424-9153), or visit their website at www.nhtsa.gov.