What 126 owners told NHTSA about the 2022 Ford Mustang Mach-e Bev Bev

On 6/4, I completed a long road trip of over 650 miles. When I got back into my vehicle to move it to where it would be parked for the night, it displayed messages for a Powertrain Malfunction/Reduced Power and a High Voltage Battery Warning. I powered the car off and back on within about 5 minutes, and the messages were still being displayed. I connected a code scanner to the car and the car had stored codes P0D0F and P0AA4. Both of these codes indicated a fault with the High Voltage Battery Junction Box, a known issue with the Mustang Mach E. I was able to drive the car to a dealer the next day without incident but am wary of trusting the vehicle to make the same trip back home.

NHTSA ODI 11742422

Vehicle shutdown while driving causing total power loss and hitting a parked vehicle. No alerts or notifications were present at the time.

NHTSA ODI 11720560

File against: Ford Motor Company Vehicle: 2022 Ford Mustang Mach-E VIN: [XXX] Safety Complaint While driving, the vehicle unexpectedly slowed down, lost power, and became inoperable, creating a serious safety hazard. I was able to pull over safely, but the sudden loss of motive power occurred during active roadway conditions. Dealer diagnosis identified a wiring harness connector failure affecting communication between vehicle control modules. After the repair, the same issue reoccurred within one to two days, again causing loss of power. The vehicle is currently back at the dealership, and the underlying defect has not yet been permanently resolved. This recurring electrical failure represents a loss-of-motive-power safety risk that may indicate a broader wiring harness defect affecting vehicle reliability and safety. Thanks and Regards INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11718385

I have a 2022 Mustang Mach-E GT and have now experienced two (2) High Voltage Battery Junction Box (HVJB) failures. First failure was in July 2023 when the vehicle had approximately 12,000 miles. I received the stop safely now message. Vehicle codes displayed via the Ford app showed a High Voltage Battery Warning and Power train Malfunction / Reduced Power warnings. I have now received this same failure and warnings again. The car currently has 54,000 miles and I was just advised by my dealer that the HVJB has failed a second time. My concern is that the replacement voltage boxes are nothing more than a Band-aid for the problem and not a permanent solution. As I prepare to receive by 3rd HVJB, I feel this is nothing more than a temporary fix until I receive another Stop Safely Now message while operating my vehicle. Please look into the HVJB failure rate for these vehicles. I am in online two Mustang Mach-E owners groups and this issue is rampant among owners. I feel this issue requires outside attention as Ford has now had 4 years to solve this issue for early produced Mach Es. Yet the issue continues to exist. Thank you for your attention in the matter.

NHTSA ODI 11687734

I was driving my car when all of a sudden it lost all acceleration and power, I was lucky that I wasn't on the highway anymore and was able to pull over safely on a side street while car was rolling still. Dealer said 12V battery fused, and I have been reading forums where this is a common issue.. In a normal ICE car when 12V battery dies while driving, car can still drive, in this case, it just stops and pops up a dozen errors about everything being broken.

NHTSA ODI 11671895

- What component or system failed or malfunctioned, and is it available for inspection upon request? According to the technician, there was a 12-volt battery in the beginning, but after staying in the shop for three days, they found that it was HVBJB, also known as the bussed electrical center (BEC). The car was recalled last July and was in the shop for about a month for HVBJB, also known as the bussed electrical center (BEC). The shop had already replaced the part last year. - How was your safety or the safety of others put at risk? The car suddenly stopped and lost battery power when I was driving on [XXX] going to [XXX]. Las Vegas, Nevada. The car turned off, and there was an error message on the screen. I could not move the car anymore. "When the car suddenly stopped, my wife and I felt like we had hit a wall at 45 miles per hour". - Has the problem been reproduced or confirmed by a dealer or independent service center? Yes, last year, it was by Galpin Ford in Los Angeles when the vehicle was called for a recall in that specific part, and now it was by Gaudin Ford in Las Vegas when this incident happened and they claim they need to replace the same part. Recall Reference Number: 23S56 - Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Yes, last year, it was by Galpin Ford in Los Angeles when the vehicle was called for a recall in that specific part, and now it was by Gaudin Ford in Las Vegas when this incident happened and they claim they need to replace the same part. Recall Reference Number: 23S56 - Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11647515

While driving, the car suddenly stopped, showed a "Stop Safely Now" warning and stopped in the middle of a busy road. Car went into Park and could not be moved from the middle of a busy road. Remained in Park and could not even be shifted into Neutral to be pushed out of the way of bust traffic. Very dangerous. No prior warning. Car had to be towed and now at deal for investigation into cause.

NHTSA ODI 11632408

At highway speeds, the power brakes failed. In order to slow the car down, the brakes pedal had to be modulated with extreme force, upwards of 100 pounds of pressure on the brake pedal. As this happened, the car raised 4 Active Alerts - Powertrain Malfunction / Reduced Power - Antilock Brake Fault - Hill Start Assist Warning - Pre-Collision Assist Not Available. It took a lot of force and distance to bring the car safely to a stop. After 20 minutes we restarted the car and it began to operate normally. The car was brought to a nearby dealer immediately, however, the dealership is unable to diagnose nor replicate the problem. ***We were extremely lucky there were no cars immediately in front of us, and that we have an extreme amount of room to stop. Had we been driving in traffic, there would have been an extremely high likelihood of an accident with injury.

NHTSA ODI 11615671

My car lunges forward randomly. I have called ford and went to ford several times.

NHTSA ODI 11608801

I was driving on the freeway when out of nowhere the vehicle alerted me to "Stop safely now". I no longer had any power and could not accelerate. I was doing 70 MPG in the middle lane and had to switch to the right lane, then to the shoulder of a busy interstate. This was extremely dangerous as I was losing speed quickly, and luckily had no one to my right side. If there was traffic I would have been at risk with anyone to my right also at risk. Once I was on the shoulder I tried to restart the vehicle with no success, eventually it just completely lost all power. This vehicle is full electric and had 76% charge at the time of the incident with 23,642 miles. I am very dissatisfied with how unreliable this vehicle was by just turning off in the middle of the road. The worst part was Ford roadside assistance took over 5 hours to get the vehicle towed to the dealership. I was stranded on the side of the freeway, completely unacceptable.

NHTSA ODI 11607805

Car was stopped at the top of a hill. Driver put the car in park and exited to talk to a security guard to raise a security barrier. Car began to roll down a hill and didn't stop until it hit a metal security gate 250 yards away. Car was totaled as result of collision with gate. No one was hurt. It would appear that the transmission/engine did not stay in park and began to roll and that none of the other safety features stopped the car. There were no passengers in the car at the time of the accident and no airbags went off.

NHTSA ODI 11605736

Just towed to Ford dealer. When car was in Drive mode, would go in Reverse. I have video and posted it to the Ford Facebook page.

NHTSA ODI 11605147

After plugging my Mach-E into a Blink Charger at Sheehy Ford in Ashland, VA my vehicle became disabled and will not go into propulsion mode. The car is now 98% charged but will not come out of Park. The dealership blames a NHTSA stop work order on a software update that in their words would resolve the issue.

NHTSA ODI 11601216

The high voltage battery junction box has failed for the second time in 2500 miles. Car left me stranded in a Home Depot parking lot as it would no longer move.

NHTSA ODI 11596846

Post HVBJB recall, one-pedal drive randomly disengages. Operators of electric cars vehicles use one pedal driving to slow down the vehicle and brake. When that system of braking randomly fails, it is incredibly unsafe. Ford is aware of this problem and it's connection to the earlier recall. I can provide additional documentation if necessary. Ford recognizes issue but has not fix.

NHTSA ODI 11585013

While driving on Route 1 and attempting to pass another motorist, a flashing red "STOP SAFELY NOW" lit on my dashboard, along with multiple warnings of a "powertrain failure". Thankfully I was near my house and was able to get home. But the FordPass App is saying that I had a high-voltage power malfunction and will need to tow the car to my local dealership. Now I am being told that the high-voltage junction box has failed and needs to be replaced (consistent with Ford Recall notice 23S56). Unfortunately, Ford hasn't produced a replacement part, and after speaking with multiple dealerships, I have been told that an updated replacement part may not be available until Q1 2024 (Or between 6-18 weeks from now). Those of us who purchased these vehicles now have $65K+ paperweights. Ford should buy back these cars, fix them, then resell them through local dealerships. Please help remedy this situation.

NHTSA ODI 11556598

I have a 2022 Mustang Mach E GT Performance edition. I purchased it new and am the first owner. The build date is September 2022 and I received a notification in the Ford Pass Mobile phone application saying: - High Voltage Battery Warning - Powertrain Malfunction / Reduced Power This is a known issue for build dates before May 2022, so my car should've not been affected, but it is. I've scheduled a service appointment for further diagnostics with the authorized service center where I purchased the car.

NHTSA ODI 11553775

On November 18, 2022 my vehicle's High Voltage Battery Junction Box (HVBJB) failed. Ford replaced this part with an "upgraded" version of this part and I received my car back on November 28th. Shortly thereafter, the NHTSA issued a recall, the solution for which was a software update that my car received. On October 10, 2023 my vehicle's HVBJB failed once again (the newer upgraded part). Coincidentally, while my car was in the shop, the NHTSA issued a second recall for this issue, indicating that Ford would be recalling the physical HVBJB. Shortly after this recall, my recall was marked as complete because I received the upgraded version of the part once again. Ford's upgraded part that is a solution to this issue has been issued in many Mach-e cars and is the standard for late '22 models and '23 models; however, in addition to my own HVBJB failing, I am hearing many instances of this newer part failing. Being that this recall stemmed from vehicles potentially losing propulsion as a result of this failure, the risk still exists (although potentially at a lower rate). I do, however, believe that Ford knows that this failure rate is still high and that their upgraded part does not provide a sufficient solution to the problem but has not been transparent with the NHTSA due to the costs associated with redesigning a third version of this part. I do not feel safe driving my family in this car because I know that it's just a matter of time before this part fails once again.

NHTSA ODI 11553856

This is the second time in 2 months that I’ve received a High Voltage Warning and Powertrain fault on my MME ‘22. This was suppose to have been fixed by a recall completed prior to my build date. I have been driving normal speeds on side streets when this happens.

NHTSA ODI 11548897

The high voltage battery junction box failed on my car at 9500 miles, and now again at 19200 miles. Failure prevents the car from running properly, or at all. The dealership is reporting that Ford has not developed an updated replacement part, and is only replacing with the same part that the vehicle left the factory with.

NHTSA ODI 11547152

Powertrain malfunction warning while driving to work on 55MPH road. This has occurred twice since buying the car new. November 14, 2022 with 9k miles was when the first warning/malfunction occurred. HVBJB was replaced. This last/second powertrain malfunction and High-Voltage battery warning occurred on May 26, 2023 with 15k miles. HVBJB replaced again. This warning resulted in reduction of power, but not full loss of power. Unfortunately, the last time this occurred was when I was attempting to pass on a two lane road. The power reduction when this warning occurred prevented me from safely passing and getting back in to my lane. Image of warnings on my Ford app are attached for details and dates. Northfield Ford (Northfield, MN) replaced the HVBJB on both occurrences. I have never used a DC Fast Charger. Most used charger is 110v.

NHTSA ODI 11539849

Was driving home, and all of a sudden I got a "Service Vehicle Soon" on the screen. and Got the following errors on FordPass App: 1- Powertrain Malfunction / Reduced Power 2- High-Voltage Battery Warning The time was around 8:30pm, the weather wasn't too hot not too cold. Was driving around 50 mph IIRC.

NHTSA ODI 11538373

The vehicle stopped moving in the middle of travel. There was no indicator or warning. The car was towed to a service center and diagnosed that the back motor of the car was broken. Ford did not have any updates nor fixing the problem.

NHTSA ODI 11536062

The HVBJB (high-voltage battery junction box) subassembly in ALL Ford Mach-e vehicles has known defects with insufficiently robust main contactors that are known to fail under normal charging and driving conditions as outlined in 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, as well as failure of other 12V systems due to inability to charge the 12V battery properly after contactors are damaged. Less catastrophic results can include failure to start, which can strand drivers and passengers in remote areas, bad weather conditions, and also 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, more robust HVBJB.​ ​ My complaint is that Ford's recall under campaign 22V412000 is a software-only attempt to prevent future damage, and does not require 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 restart 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 without a known failure risk.​ Thank you very much for your time.

NHTSA ODI 11510276

faulty high voltage battery junction box NHTSA Campaign Number: 22V412000

NHTSA ODI 11489060