What 334 owners told NHTSA about the 2021 Ford Mustang Mach-e Bev Bev

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. Any internal damage to contactors is not externally visibley, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, power brakes and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships NEED equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed 'beefier' components.​ ​ My complaint is that Ford's recall notice 22s41 is a software-only band aid and does not require removal of the parts KNOWN TO FAIL. These parts should be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle.​ I suffered a failure related to this post-recall and had a sudden and permanent loss of power while driving at Texas highway speeds (70mph) in congested morning traffic. Fortunately I was able to make my way off the highway but other conditions could have ended up worse. ​ Software "fixes" are not the solution and the actual problem of the defective parts need to be replaced in the affected models to avoid possible injuries and fatalities from these vehicles.

NHTSA ODI 11475350

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41 NHTSA Campaign Number: 22V412000. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed 'beefier' components.​ ​ My complaint is that Ford's recall notice 22s41 ( NHTSA Campaign Number: 22V412000) is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle.​ ​ I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new 'beefier' parts.

NHTSA ODI 11475108

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed more robust components that conform to higher electrical standards. ​ My complaint is that Ford's recall notice 22s41 is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle.​ ​ I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new more robust parts.​

NHTSA ODI 11475208

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed 'beefier' components.​ ​ My complaint is that Ford's recall notice 22s41 is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle.​ ​ I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new 'beefier' parts.

NHTSA ODI 11475000

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed 'beefier' components. My complaint is that Ford's recall notice 22s41 is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle. I have no confidence taking this car far from home with my family until a real fix is instituted. I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new 'beefier' parts.

NHTSA ODI 11474395

While returning from vacation, driving home on the highway, our car suddenly stopped working. We had been traveling at approximately 65 mph on SR 1 in Delaware when I accelerated to pass another vehicle and the car suddenly jolted forward and the engine seized. I received a warning to pull to a safe location as soon as possible. Thankfully, we were able to pull the car over to the shoulder of the highway without incident. The cars electrical system gradually shut down, limiting our ability to place the vehicle in neutral for towing. Approximately 250 miles from home and forced to wait more than 2 hours in the 90 degree weather with no AC, we were forced to bring the car to the nearest ford dealership in new castle Delaware. Since the battery and power completely failed, the dealership had to jump the 12 volt battery several times to get the car back in neutral to remove the vehicle from the tow truck. We needed to find our own car rental as neither the dealership nor ford customer service would assist with getting us back home to NY.

NHTSA ODI 11473016

My vehicle was built with under-specked high voltage battery joint assembly bracket. The failure of this connection has caused many incidents whereby the car cannot start, or suddenly stops while driving. The part is either not to original specification or was not designed correctly. In either case, providing a SW fix to simply limit the voltage does not actually prevent or correct the problem. As this fix has rolled out, there are numerous reports of the issue still happening. This is because the fix doesn't fix the original condition, it only serves to limit the scope going forward. But if the part has been in use for 2 years as mine is, then the damage has already occurred and the fix will not prevent my issue. The appropriate fix for the problem is a replacement HVBJB, which Ford is only installing AFTER the incident occurs. This is totally unacceptable and is simply an accident waiting to occur. The SW fix is analogous to the original attempt by GM to correct the Bolt battery fire situation. Eventually, the batteries were replaced, which was the correct response. I am simply demanding that Ford follow a similar path. Consumer stated number for NHTSA Campaign Number: 22V412000.

NHTSA ODI 11473149

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed 'beefier' components.​ ​ My complaint is that Ford's recall notice 22s41 is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle.​ I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new 'beefier' parts

NHTSA ODI 11472877

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed 'beefier' components. My complaint is that Ford's recall notice 22s41 is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle. I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new 'beefier' parts.

NHTSA ODI 11472707

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed 'beefier' components.​ ​ My complaint is that Ford's recall notice 22s41 is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially 'stranding me' in unsafe conditions unable to re-start my vehicle.​ ​ I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new 'beefier' parts.​

NHTSA ODI 11472834

On May 20, 2022, for the second time in a month my 2021 California 1 Mach e has had a catastrophic failure. It is less than a year old with 21,000mi. First time (April 20, 2022) I pulled out onto road after fast charging. Tonight, I started driving out of parking space after shopping. Emergency bells go off, all kinds of alerts and the car dies. You cannot get the gear cluster to turn...at all. Car will not turn off either. If this happens on a highway, it could be life endangering. First time it happened I was in Charlotte and Ford Dealer (Capital Ford) said it was 12v battery issue. Said they fixed it. I took it in to Palmetto Ford in Charleston to have it investigated further and they said it was fixed. That was two weeks ago. Now it's happened again. In second incident on May 20, I called for towing. As truck showed up, my car started normally (i had tried several other times before). I am still taking into Palnetto Ford Dealer. The Ford Motor Company needs to fix this before someone is killed. Documenting this for myself and others. This is happening to other Mustang Mach E...because I have seen the issue written about in online forums. The problem onset is sudden and catastrophic, meaning the car just dies. First time I was on a busy road traveling 30mph and managed to roll into a parking lot. Had their been traffic I could have been hit. Second time, I was in a parking lot traveling 5 mph and blocked an entire lane for 10min. To emphasize: two dealers looked at vehicle after incident 1 and said issue was fixed. Now I have to go back into Dealer again. Thank you for investigating.

NHTSA ODI 11465548

While parking in a garage the vehicle unexpectedly accelerated and ran into a wall. Anyone in or around the car may have been seriously ignored. The issues has happened twice but can not be reproduced by me. There we no indicators that the event was about to take place There is a recall for this on the vehicle type but not for the date of my manufacturing.

NHTSA ODI 11465417

Bricked Mach E Extended Range with 10K miles and recently completed the roof and windscreen recall the week prior. Went to brunch and then came out to a car that would not start. Warning of "Stop Safely Now" even though the vehicle was driven to the location and then sat for 2 hours and was currently parked and still gave us this message. Low voltage (12 Volt) came in slightly low at 12.6 VDC. Attempted two jumps from another vehicle and a higher amperage tow truck with no change in error code nor would the vehicle "start". We resulted in doing a tow to a dealership for potential repair. Dealership has had it now for going on the third week. They are citing the replacement of the battery bus where the Low Voltage 12 VDC interfaces with the brains and main battery system. This has been cited before in the Mustang Mach E blogs. Replacement part is on hand but the dealership has a specialist being flown in to remedy the replacement part installation. Read in Mach E forums of similar problems where the battery became low and the vehicle was then disabled from engaging the drivetrain. Overall problem gave us pause on ownership and we will qualify for the Lemon Law buyback for CA if it comes to that. Looking to see if repairs will be complete this week.

NHTSA ODI 11465012

After charging at Electrify America using DC Fast Charger, car windows stopped working, then safety alerts started flashing "Charge State Error" and "Stop safely now!" alerts. Car would not go forward but would go in Neutral some tries. Flatbed was able to load car and haul to closest dealer. Tech said High Voltage Junction Box went bad and needed to be replaced. 3 weeks later, part is replaced but windows don't work. Dealer says it will be 2 more weeks before windows can be repaired.

NHTSA ODI 11464454

Vehicle would not start after a brief stop, with a "Stop Safely Now" error. Vehicle could not be shifted out of Park, and could only be shifted into Neutral using the Emergency Tow Mode. Vehicle was towed to nearest Ford dealer, and the High-Voltage Battery Junction Box (HVBJB) failed and required replacement. This is a known issue that has affected many similar vehicles of the same make, model, and year.

NHTSA ODI 11464507

I received a “Stop Safely Now” message upon returning to my vehicle at the end of a work day. The vehicle would not shift into drive, but accessory power did work. It was late at night and in a hospital parking structure, I was forced to leave the vehicle there overnight. After some unsuccessful troubleshooting the next day, I had to call a tow truck and have the vehicle brought to a dealer for repair. It was diagnosed with a faulty BECM (Battery Energy Control Module). After repair, I have not yet seen a repeat occurred the issue.

NHTSA ODI 11464559

I was stranded in a parking lot in the evening when my car wouldn't start. The vehicle displayed a "STOP SAFELY NOW" message and I couldn't get the car to move on its own. This happened on April 13, 2022. My safety was at risk because I was in a parking lot at night and unable to engage my car. I had to call and wait for a tow truck. The Ford dealership, in consultation with Ford engineers, confirmed that it was due to a faulty High Voltage Battery Junction Box (HVBJB) and it had to be replaced. With the faulty HVBJB, the car was undrivable. The HVBJB was inspected by Ford personnel and determined to be faulty. It was replaced under warranty. There were no other messages or warnings before my car failed to start. No prior symptoms. I drove normally to a store, parked the car, and when I returned to my car it failed to start.

NHTSA ODI 11463755

Was driving 55+ mph on freeway, was told by the car to 'stop safely' Had no accelleration, no power steering, came to a stop at a stop sign, could not shift to neutral to move it.

NHTSA ODI 11462062

On 4/1, while entering the FWY @ about 50 mph under moderate accel, big thump (felt like the trans fell out), drivers display cycled thru multiple errors with "stop safely now" repeatedly flashing. Throttle went dead, speed dropped to 35 and steadily decreased. Was able to slowly exit FWY @ next exit, rolled thru light @ bottom of ramp and pulled over to the side of a busy side street. Came to a stop & car would not move. Put in park, cycled on/off several times. Would not come out of park. Tow truck arrived. Found emergency tow function in the main display. Tow driver hooked up front, put rears on dolly & towed to dealer.

NHTSA ODI 11460408

Car was parked in my home garage and would not start, displaying "Stop safely now." Vehicle appears to have code P0AA1 Hybrid battery positive contactor - circuit stuck closed. Many other Mach-E vechicles are exhibiting this defective part in the high voltage battery system, which appears to be the Battery Electrical Control Module (BECM). Ford appears to be aware of this issue, and, unconfirmed, has stopped production of the Mach-E to canibalize parts to fix vehicles that fail. However, some are less lucky than me and had their car stop dead while driving on the highway, and Ford should not be waiting for vehicles to stop and strand people before fixing this serious defect. Please see here for more info on my situation: https://www.macheforum.com/site/threads/%F0%9F%98%ADmach-n-cheese-stop-safely-now-%F0%9F%98%AD.16174/

NHTSA ODI 11459506

As the vehicle was braking to a stop at a stoplight the rear motors began chattering. The vehicle stopped and gave multiple error messages including "Shift System Fault" and "Stop Vehicle Safely." It locked the parking brake and could not be moved. It was stuck in the middle of a busy intersection on a county highway. It could not be driven or pushed out of traffic until the error cleared. It was a hazard to the occupants and other drivers on the road. 911 was called to get support with traffic. There was no indication before this failure occurred. It will be going in for service in 2 days. This is the second occurrence of the failure on this vehicle, the previous one at 2011 miles.

NHTSA ODI 11454597