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

I had my 2021 Mustang Mach-E updated with the recall software last year. In July of 2022, my High Voltage Battery Junction Box (HVBJB) still failed, giving me a service vehicle soon and SEVERELY reducing power WHILE driving. I was on the freeway and my car just started reducing speed since I was trying to pass someone and I almost hit them. I received the new HVBJB from my dealer and had been fine since. Then a couple of weeks ago, I received the errors AGAIN with this "new and improved" HVBJB that Ford said is more robust and not supposed to fail. Same thing, on the same freeway I commute (73 toll road in California). I was passing someone and the car hit me with all these errors and SIGNIFICANTLY reduced my power. Like 66% reduction. I had to get back into my lane and was able to get back a safe speed but you basically have no power to pass. This is unacceptable. I received the "new" part and yet get a failure AGAIN? On a normal commute, not at the track, accelerating to show off the EV acceleration, just DRIVING! Please make them fix this for real. My dealer said there was a new bulletin that came out after my first repair that has an updated part number, but it is not a true revised part, meaning the internals are actually differnt, it is more a housekeeping part number update due to something as simple as the sticker being in a different spot, some backend thing, etc. There has been no revision to the components that fail since they "fixed" the part back in 2022.

NHTSA ODI 11539777

On Friday 8/18/23 I was driving down a major freeway and my Mach-E jolted violently. I then received a "Stop Safely Now" and "Service Vehicle Soon" message. The vehicle lost all power at this time. Being on a very busy freeway my safety was at risk and I was luckily able to coast over to the right shoulder. The car refused to "start" after pulling over however the 12v battery did work so I was able to use accessories. Once towed to the dealer I was able to confirm a P0AA2 TSB code that indicated that a conductor was stuck open on the high voltage junction box. This was supposed to be fixed by a previous recall software update that FORD uploaded to my car however that was not the case. I am now without a car for 2 weeks but more importantly I am concerned for the safety of other Mach-E drivers as I am reading that this can happen again even after a hardware fix.

NHTSA ODI 11539803

Did a DC Fast Charge at Electrify America in Astoria Oregon from 62% to 87%. Used wide open throttle to pass car on mountain climbs about 4 times with in about 30 minutes of charge. When accelerating on to Interstate 5 south received the Service Vehicle Soon warning - Ford App said stop and get car towed. Continued to drive for 22 miles and made it home. Charged car to 85% on Level 2 charger and drove it dealer on Sunday morning, no issues driving. Dealer had the car for one week and replaced the High Voltage Battery Junction Box and so far the car has been fine. Dealer provided a rental car at no cost their service was excellent. However, I thought it would be best to report this incident in light of the recent news.

NHTSA ODI 11539827

Powertrain failure- reduced/loss of power High voltage battery warning- unsafe to drive

NHTSA ODI 11538526

I went to start the vehicle and it gave me a red warning "stop safely now". It was already stopped and would not start at all. It had plenty of charge on the battery pack. It's been at the dealer for nearly two weeks and they have had to order the HVJBC, I believe. I am fortunate that it didn't fail while driving or parked in a place which was inaccessible to a tow truck. The forum I read recommended making a report. This seems to be an all to common problem with this car and can lead to sudden acceleration or deceleration while in motion. Had had received an earlier yellow warning for "service vehicle soon" and took it to the dealership and they assured me they had updated all the software (in the hopes of preventing the "stop safely now" problem). Obviously, that didn't work.

NHTSA ODI 11511316

The contact owns a 2021 Ford Mustang Mach-E. The contact stated while in reverse(R) and driving approximately 3 MPH, the vehicle would independently brake suddenly. The contact stated that the parking brake light was illuminated. The contact stated that the brake failure was intermittent and occurred without warning. Additionally, the contact stated that the vehicle would lunge forward while stopped at a traffic signal without depressing the accelerator. The vehicle was not taken to the local dealer; however, the local dealer was contacted, and the contact was asked if she had duplicated the failure. The contact stated that she could not since the failure was intermittent. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 21,000.

NHTSA ODI 11493699

on 8/22/2022 received a powertrain malfunction notice by Ford. Since that time on four occasions the vehicle has lost power causing a significant jerking and loud thud. It loses all power. This has happened twice after Blue Cruise has disengaged. Two other times include when the vehicle was placed in drive or reverse. It also caused a lurching motion after it engaged without the foot on the accelerator.

NHTSA ODI 11487527

Two problems on multiple separate occasions occurred. 1st problem - more than twenty (20) times car had suddenly accelerated or slowed down while driving with cruise control. This supposedly should have been resolved with an update that was downloaded around a month ago. Nothing changed, car still accelerates or slows down randomly. 2nd problem - occurred at least five times. Car suddenly loosing power while entering the traffic including entering highway. Drivetrain malfunction warning was displayed on dashboard after last lost of power when entering intersection. After latest incident on September 13th car is being repaired at the dealership.

NHTSA ODI 11486304

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

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

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

Power loss a week ago. Had to have Mach E towed to dealership. Ford is aware of Mach E power loss.

NHTSA ODI 11470363

While legally passing a car on a 2-lane highway, at over 50+ mph, the car lost motive power and began to shut down leaving me with no power facing on coming traffic. I had no choice but to force other cars to slow down behind me, causing another hazard, in order to get to the side of the road. I could have been killed in an oncoming car collision.

NHTSA ODI 11470258

The contact owns a 2021 Ford Mach-E. The contact stated while reversing from his driveway, he shifted into drive and depressed the accelerator pedal. However, the vehicle accelerated at high speed independently. There was no warning light illuminated. The contact continued to drive. The contact stated that the failure reoccurred the following day. The contact stated while his wife was exiting the carwash and making a left turn with a passenger in the front passenger seat, she shifted from neutral into drive and depressed the accelerator pedal. The vehicle accelerated at high speed independently and crashed into the block wall. The air bags deployed. The contact's wife sought medical assistance and was informed that she had sustained a fractured rib on the left side of her body, pain on the shoulders, and pain in the rib cage. The passenger occupying the front passenger's seat sustained pain all over her body and a bruised rib and she sought medical assistance. A police report was filed. The vehicle was towed to a tow lot where it was totaled. The dealer was not notified of the failure. The manufacturer was notified of the failure. The contact became aware of NHTSA Campaign Number: 22V333000 (Vehicle Speed Control, Power Train), which he associated with the failure. The failure mileage was approximately 18,000.

NHTSA ODI 11466999

Driving our BEV Mach E at a normal speed, we got an error code, "Pull to the side of the road safely / stop safely" on our instrument display. The car turned itself off, and we had to slowly coast to the side of the road, which caused a lot of potential harm with other drivers not expecting our sudden course change - We activated our hazards, though. After cycling the car on/off, we were able to finish our drive home (about 8 more miles) with no further error codes. But this completely disabled the car and was extremely dangerous. If this had happened on the freeway or at night, and/or the vehicle would not have been able to be restarted, this would have been EXTREMELY DANGEROUS and is UNACCEPTABLE. Ford must be responsible for this, and must take action. Ford must fix the high voltage junction box, before someone is killed by this poor design. Thank you for taking the time to look at this note. This was VERY scary, and VERY dangerous.

NHTSA ODI 11466150

Travelling from WI to NC using Electrify America DC fast chargers along the way. While in NC, got Stop Safely Now alert on screen and had to immediately pull over and stop where there was no shoulder. Could not move vehicle in any way after this. Could not put it in N, could not put it in Emergency Tow Mode. Had to wait 8 hours for tow with proper equipment. Issue was caused by failure of HVBJB - High Voltage Battery Junction Box which needed to be replaced.

NHTSA ODI 11465461

During a normal maintenance service appointment car had a Stop Safely Now error message appear. Diagnosis was a bad High Voltage Battery Junction Box and BECM. With were replaced and car has been fine since then

NHTSA ODI 11464572

Second time this has happened. A message will pop up saying “please stop safely now” once you stop you can not get it out of park. If your driving you are stuck wherever you are. I was stranded the first time with no heat in 20 degree weather. They fixed it after having it for a month then it just happened again today in 80 degree weather with my kids in the car. This has happened to multiple other people as well.

NHTSA ODI 11464365

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

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

Second time in less than two weeks: Vehicle started making grinding noise, and a warning came up on the screen SHIFT SYSTEM FAULT, service soon. But the car came to a halt a hundred feet later, then would not get in or out of any gear, parking brake could not be released, vehicle could not get into Neutral so not able to push or roll it. I was barely able to get out of an intersection today (Nov 11), and rolled into a parking area on Oct 30 with the same fault. After about a half hour, vehicle could be moved but would show the fault shortly afterwards, locked up. Vehicle was towed on Oct 31 to dealership, they checked fault codes, performed some software updates and test drove 4 miles. They returned the car. Today, same thing happened. Car was at an intersection. Called AAA and still waiting for them to schedule a tow truck (required wheel lift and dolly). Fortunately I was on back roads today but this is a serious problem which would have been much worse on a highway. Car is not drivable. Again, this is the second time in two weeks!

NHTSA ODI 11440157

AS I WAS DRIVING DOWN THE ROAD (IN MOTION / CITY STREET) AT 30 MILES PER HOUR IN MY BRAND NEW (4 WEEK OLD / 2200 MILES) ALL ELECTRIC FORD MACH E, THE DISPLAY FLASHED MULTIPLE WARNING LIGHTS THAT CAME TOO QUICKLY TO DECIPHER, AND THEN THE CAR WENT DEAD. I WAS ABLE TO PULL OFF THE ROAD AND COME TO A STOP. AT THIS POINT THE CAR WAS COMPLETELY DEAD. EVEN THE HAZARD LIGHTS WOULDN'T WORK WHICH MADE THE SITUATION DANGEROUS SINCE THE CARS BEHIND ME COULD NOT TELL THAT THERE WAS A PROBLEM.

NHTSA ODI 11415152