2022 FORD MUSTANG MACH E Complaints

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.

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.

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.

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.

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.

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.

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.

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.

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”.

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.