The Ford Mustang Mach-E’s Recalled Batteries Are Being Rechecked Due to a Persistent Issue

Despite an OTA software update for the EV’s recalled battery overheating problem in 2022, some owners are reporting problems once again.

Due to a safety issue that might cause the car to become immobilized or lose power while driving, Ford has warned dealers to delay deliveries of the 2021 and 2022 Mustang Mach-E.
Ford told Car & Driver in a statement that the issue lies in the battery’s main contactors, which can become overheated and prevent the vehicle from starting or functioning.
Ford will issue a software update to 48,924 Mach-E crossovers in the United States to solve the issue. A statement from the company claimed it “has not issued instructions to stop driving vehicles under this safety recall.”

UPDATE 8/21/2023: After 12 Mach-E owners reported additional battery failure issues in their vehicles after the recall was implemented, NHTSA began a new investigation into the recall discussed in this article. The National Highway Traffic Safety Administration has released a report detailing its inquiry into the matter, which states, “High-voltage battery contactors may overheat, resulting in a loss of motive power.” More than 64,000 2021 and 2022 Mach-E crossovers might be recalled if the inquiry finds enough cause.

Update (6/15/2022): The National Highway Traffic Safety Administration has published a recall report on the Mustang Mach-E issue. Furthermore, at least one owner has lodged a complaint about their vehicle on the NHTSA website, claiming, in part, that “my 2021 California 1 Mach E has had a catastrophic failure.” It has been driven for less than a year and has already clocked over 21,000 kilometres. On April 20, 2022, I accelerated for the first time and drove out onto the road. In the evening, I finished my shopping and began to leave the parking lot. There are sudden alarms and the automobile stops working. You have tried and tried, but the gear selector would not budge. The car also refuses to shut off.

Approximately 48,924 Mustang Mach-E electric vehicles will be recalled by Ford to address a battery issue that might result in the vehicle losing power while driving or failing to start. According to Ford, the primary contactors in the recalled vehicles’ batteries may overheat and cause a fire.

Overheating of the high-voltage battery main contactors can occur during DC fast-charging and repeated wide-open-pedal events, Ford said in a statement released today. Arcing and deformation of the electrical contact surfaces due to overheating might leave a contactor open or cause it to weld shut. Loss of motive power due to an overheated contactor opening while driving increases accident risk. Ford reports that there are no active investigations into the issue, and the NHTSA recalls website currently shows only one complaint from an owner.

The automaker informed C/D that it intends to issue a software update for the Mach-E via an over-the-air repair, but impacted vehicle owners also have the option of visiting a dealership. Ford has promised to release a software patch for the SOBDMC and BECM (Battery Energy Control Module). NHTSA’s recalls site currently lacks details about the impending recall, although this is likely to change soon.

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