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

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

On this vehicle, it looks like I may have some arcing on the pins on my car where the charging port hooks up. This car has burnt up two charging cables. What I would like Nhsta to ask Ford is nowhere in this customer satisfaction program does it say they will replace the burnt pins on anyone's cars if they have them. Also, I do not see any recall for this issue as every single mach e that has any chance of having burning pins in their charging port should be inspected. I have received this letter on my 2022 mach e and 2023 one and I will make a complaint for both. There should not only be a recall opened up on this to properly inspect every single charging port for any kind of arching as any kind of arching may have caused damage not only to the pins but the entire electrical system or any one of the components that go from the pins to the batteries. Furthermore of a recall I also ask that an investigation be opened to Ford itself since they cannot tell customers who pay a ton of money for there vehicles why they did not open a recall or notify Nhsta in the first place. This is even worse in my opinion then the last two recalls when they tried to give us software knowingly having an updated part that was more robust for the battery control module to have to be investigated in order to replace it. This should not be tolerated. My safety, my family's safety, and everyone else's safety who owns one of these vehicles is the main importance to me. Like I said looks like I may have some arching on my pins on my car charging port but who would know Ford is not even going to replace them or inspect them there is no recall for this that I have seen. Shady as usual shame on you Ford I hope NHSTA drops the hammer on you this time and the last time.

NHTSA ODI 11553871

The HVJB failed once again, disabling my car. This is the second HVJB I’ve had since purchasing the car April 18,2022. The car goes into a limp mode making it unsafe for highway use.

NHTSA ODI 11553046

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

Vehicle experienced the recalled HVBJB failure around November 21, 2022 at 13,000 miles. The failed device was replaced. Around July 12, 2023 at 23,000 miles, the replaced HVBJB device failed again and was once again replaced. It seems that the replacement device does not resolve the issue. Both times, the vehicle was traveling on the highway and the vehicle performance was instantly restricted causing a dangerous situation where I had to immediately move over to the right lane without any acceleration power to navigate around large trucks.

NHTSA ODI 11546519

I am going to try to explain this as best as I can. Ford has faulty charging cables that they know about and have not recalled voluntarily. This I have an issue with because it is causing the battery on my car to overheat and put it at a potential risk of catastrophic thermal runaway incident. I have had two charging cables go bad on my car. I just got my car back today and I noticed the new cable has a new part number on it as well as different types of wiring marked on the outer portion of the top cable. This is the gauge of wiring that is being used to plug into the outlet of my home to the actual charging conversion. Look at the old and new cable pictures and notice the white markings on these cables the gauge or wiring is different. Now the part number of the one on the white car I am not sure at all which one was turned in as I no longer have it anymore but what I can tell you is on the white converter itself with part number LJ98-10f868-AL is the new part number cable which I just got and have no issues with. The other one part number LJ98-10f868-AK is the older part number cable that I have seen the amber light staying on that says that it's in an undercharging condition due to overheating. So with this said Ford is aware there is a defect in the charging cables of previous models prior to AL. I have had two other charging cables go bad before I just got this AL one how is this possible with no recall? These prior model charging cables are putting stress on the electrical system of the car. I can tell because with these old cables I hear the cooling fans coming on super loud which yeah the cooling fan is supposed to come on but im pretty sure the undercharging should not happen on the cable unless the battery is overheating. With this said you must open an investigation to look into these charging cables and what is changing the part numbers. It seems to me they are using different gauge wiring and type of wiring for the part that plugs into the wall.

NHTSA ODI 11545715

While driving on I-40 East between Raleigh, NC and Benson, NC I was trying to use the Blue Cruise self driving feature on my Mache. The system is frightening to me because it tends to default towards the marker between lanes and requires more attention than so called hands free driving is supposed to need. However, in this situation, there was a stretch of the highway where the lane markers were half white and then half black stripes. When I hit that stretch the car veered over the lane markers into the passing lane and if I hadn't resumed control, would have taken me completely into the other lane. The dash indicated that the system was in control of the car for the entire time. It had not disengaged at any point.

NHTSA ODI 11545115

Suffered a “ stop safely now” error message. The battery warning light came on. Vehicle was parked at the time and suffered this error which wouldn’t let me start or shift into gear. I already had the HVJB replaced last year, September 2022.

NHTSA ODI 11543741

While driving the vehicle in the highway the service/malfunction indicator light (MIL, wrench symbol) turned on and the vehicle dramatically lost propulsion power limiting my acceleration/speed. I opened the Ford Pass App on my phone and the following messages were shown regarding the issue: "High-Voltage Battery Warning and Powertrain Malfunction/Reduce Power". The message in the app also indicated to contact the dealer immediately. I would estimate that max acceleration was instantly reduced over 30%, causing a great concern while cruising at highway speeds. Previous to the date of this incident, the warning/check engine light never turned on. I made the next exit to use secondary roads as a precautionary measure since the max acceleration was limited. I am very active in various Mach-E forums, and this is a well-known issue for Ford. These messages are the ones related to a potential design problem with the High Voltage Battery Junction Box (HVBJB) included in my vehicle (Mach-Es built on or before May 28, 2023). My production date was January 2022. This vehicle got the safety recall #22S41 (software update) at the dealer last year. The software basically allowed the driver to get these warning messages if issues with the HVBJB contactors were detected. It is noteworthy to mention that I did not get the “Stop Safely Now” message, which would have made the vehicle undrivable. Next morning the wrench symbol disappeared from my instrument cluster. Ford issued a technical service bulletin #23-2257 to address a fix, which will involve the replacement of the potentially defective HVBJB for a redesigned one. The dealer indicated the remedy Ford provided was the software update, however multiple owners have reported the replacement of the potential defective part by Ford can only be done if the vehicle is totally inoperable showing the "Stop Safely Now" message. A sudden loss of propulsion while cruising at highway speeds is a safety concern for driver and others.

NHTSA ODI 11543466

So I have had 2 240v Ford charging cables go bad with a solid amber light on it and a pulsating blue light in the middle and no red light. This means according to the chart I saw online that the charging is reduced because it's overheating. So I drove it around on August 29th,2023 with a high temperature outside of 105 degrees F that day. The low I believe in Murrieta, CA that night was 70 degrees F. Since it's charging in the garage, you have to account for an extra 10-18 degrees F of heat since most garages are not air-conditioned. This coupled with the high voltage battery connector failure recall that is also currently being investigated leaves me to believe the battery itself may be overheating causing the high voltage battery connector to weld itself shut and 240v Ford charging cables to fry. With both of these issues currently happening I believe it puts us at a higher risk for a catastrophic thermal runaway event. My recommendation would be to check Ford's testing of the electrical battery system. Was it tested driven during 105 F weather then charged overnight multiple times on a 240V Ford charging cable that comes with the car? Was the fact that 10-18 Degrees F that a garage is much hotter then it is outside? I have had two charging cables fail with under 25k miles. This leads me to believe the battery is overheating and catastrophic thermal runaway is at a greater risk with all these issues. I do not want this thing to go into catastrophic thermal runaway while in my garage and hurt my family.

NHTSA ODI 11543245

HVBJB failed on 2/1/23. We received the stop safely now alert and the vehicle would not start. Luckily not while driving, but leaving myself and daughter stranded at night. This is a known issue and there is a recall software patch available through Ford for the issue. It had been completed prior to this event. The software update Ford offers isn’t sufficient to solve the problem.

NHTSA ODI 11542556

While driving on the freeway at about 65 mph through a gradual left bend in the road, with fully active SuperCruise (lane keeping, active cruise control) and fully hands off, the vehicle suddenly veered into the adjacent right lane. The vehicle moved into the adjacent lane at a high rate, and could have resulted in a heavy side impact to a vehicle driving in that lane (and potentially rippling into the lane to the right of that as well). Throughout the deviation, SuperCruise remained active without warning lamps or any inducement of driver takeover. I caught the malfunction and manually overpowered the steering to bring the vehicle back into the original driving lane. The vehicle has no active open recalls, and is operating with the latest firmware updates installed. The vehicle has not been inspected by dealer, manufacturer, or any other group for any relating issues.

NHTSA ODI 11542066

Upon startup and without warning, the sound system emitted a very startling ear-piercing noise followed by very loud static which did not stop when radio was turned off. It finally stopped when I turned the car off but static started up again each time it was turned on. An hour later when the car was turned on it did not occur. It was so loud that the car was undrivable not to mention how startling it was at the onset. I actually jumped out of the car when it happened. I’ve scheduled a service visit for next week.

NHTSA ODI 11540639

I bought a 2022 mustang Mach e. Which was supposedly fixed at the factory in regards to the HVBJB issue. However, in mid 2023, my vehicle suffered a limp mode/warning about reduced power while on the interstate, was limited to about 60mph with very poor acceleration. Was diagnosed by ford tech as a failure of the recalled part and required HVBJB and BECM replacement, similar to 22V-412 recall. I think this should be added to RQ23004 investigation, as these vehicles had both the new hardware and software and were supposed to be “fixed”.

NHTSA ODI 11539783

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 stock suspension is dangerously defective. Both front and rear suspension do zero dampening and rebound necessary to keep the vehicle tires in contact with the road. When driving 50 to 70miles an hour on the highway, whenever I encountered a regular dip on an overpass, the front and rear wheels go slightly airborne. On several occasions driving on I-69 in Houston area, at one of the curved overpasses near Hilcroft Rd, slightly rainy wet and slick highway road, at 55 mph, my Mach E went airborne for a split second after passing thru one of the normal dips or seams on the concrete highways. I felt the vehicle was out of control going airborne for a split second and then regaining control after the up and down bounce subsided. I complained to my dealer (Helfman Ford). Their response was... they couldn't do much about the suspension because there were no recalls nor TSBs. However, they were able to log the complaint directly to Ford. I don't know the exact date of occurence, but one of the instances was sometime in the month of April 2023.

NHTSA ODI 11538480

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

They Crystal of they roof is broken i Made a complaint at they Ford dealership but they denied they claim because they said something hit on they roof anda i'm sure that nothing hit

NHTSA ODI 11535695

Vehicle adaptive cruise control was set at 35mph in a 35mph speed zone as I approached a stop light I tapped the breaks which should have disengaged the cruise control but instead the vehicle speed accelerated. Warning light stated cruise control was disengaged with gray line through speed indicator. I stepped on the brakes hard and the vehicle did stop and accelerator stopped. At no time was my foot on the accelerator pedal as well floor mats were not touching the pedal. Outside vehicle was clean and camera unobstructed. This just started after update 4.2.5.

NHTSA ODI 11533641

On 3 occasions in the past month I have been driving down the road and, without any action from me, cruise control has turned itself on, with a speed set above the speed limit. I noticed it because the car accelerated to reach the target speed (which was an unsafe speed). I immediately braked and turned off the cruise control. The first two times it happened, I was pretty sure I had not accidentally activated cruise control by touching the button on the steering wheel. The third time, I was on a straight stretch of highway and was 100% sure I had done nothing to activate cruise control I had not used cruise control at any point from the time I turned on the car until the time this happened. I was between 10 and 15 minutes into my trip when this occurred.

NHTSA ODI 11529784

After charging for the first time at a DC fast charge station to 80%, I resumed my trip and drove about 3 miles to merge onto the expressway, my screen panel said "safely stop now", with a turtle logo and battery icon coming on. my car then came to a complete stop within a few seconds in the middle of the on-ramp leaving me stranded. I repeatedly tried to turn the car on and off to see if i could get it to accelerate again but to no avail. I was stuck in the middle of the merge lane where my car would not move. After trying several attempts to rebooting, locking, turning off the car completely for 10-30 minutes, nothing worked. Although the accessory power said it was active there was no AC. After a couple of hours of waiting for a tow truck that would actually work with an EV, I locked the car again and tried to start. There were no warning lights so I tried to go to get off the expressway. After 3 miles at 70mph, the same warning lights came on and the car started to decelerate and then stopped. Luckily I was able to get over to the side of the interstate. After still waiting on tow truck for another 2 hours, lights inside the car started blinking, a loud banging sound started coming from the car and then nothing would work. Screens were black, doors were locked, windows wouldn’t roll up. No accessory power at all. It was 95° in Florida sun and I was completely stuck in the middle of nowhere at the mercy of any tow truck that would come help. It took 6 hours to get someone to come. He jumped the 12V battery and the car turned on and we loaded it onto the flatbed and took it to the dealership. Waiting now to see what is happening.

NHTSA ODI 11525550

On at least 8 occasions the car unintentionally shifted into cruise control and accelerated immediately. This usually happened while driving under 30 mph and rapidly accelerated to a much higher speed, sometimes set as high as 70 mph. On 3 occasions this happened in a parking lot and 2 occasions in a bank drive thru with a vehicle only a few feet in front of me. Immediate emergency braking was required to avoid an accident with two very close calls within 1-3 feet of vehicle in front of me. This experience has been reported by numerous persons on the Mach E Forum (similarly complaining of near accidents) and the general conclusion is that the button that activates cruise control is both unnecessarily super sensitive and poorly located so that it is engaged by the lightest touch of your left palm, base of your left thumb, or another finger as you move it across the steering wheel. Please note that the form below does not allow for numerous occurrences.

NHTSA ODI 11524686