2021 FORD MUSTANG MACH E Complaints

I am filing this complaint regarding the potential failure of the High Voltage Battery Junction Box. There have been many failures reported on the forums some experiencing multiple failures. Ford provided a software update that supposedly predicts an impending failure reducing available propulsion power. I do not feel comfortable driving a vehicle with a ticking time bomb. Losing propulsion power while driving at highway speeds could result in a serious safety senerio. I would like to see Ford provide a real fix.

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contacts that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only AFTER the 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 contacts 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.?

After receiving the remedy to NHTSA campaign 22V-412 on Aug 5, 2022 via a Ford Power-Up over-the-air update, my high-voltage battery contactors still overheated and failed on Oct 25, 2022, requiring warrantied replacement by my Ford dealer on Oct 27, 2022.

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.

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.

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.

Driving my Ford Mustang Mach-E has always been a source of joy, but a recent 250-mile road trip unveiled a concerning issue. The dashboard flashed an error message at least 10 times, warning of "Service Front Camera" and "Pre-Collision Assist Unavailable." Each occurrence led to the disengagement of the adaptive cruise control, stripping away my confidence that the car would automatically brake for vehicles ahead. This intermittent malfunction, combined with the unpredictability of its onset, has cast a shadow over my driving experience. It's deeply unsettling to be constantly reminded of potential risks, especially when relying on safety features that once felt so dependable. The trust I had in my car's safety systems is now tinged with apprehension.

This is the second time they have to replace the HVBJB on my car . First time was on 9/2022 and now again on 8/16/2023. the car is in the shop for the same issue.

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

Windshield loose adhesion from paint separation from primer. The Glass windshield in my car had a small chip occur while driving at 40 mph.. about 60 seconds later a crack appeared about 18 inch long lengthwise across the windshield. after being parked will ordering a new windshield the crack grew to 90 percent the horizontal width of the windshield. Later while having the windshield removed for replacement by the owner New View glass in a cool indoor environment we examined the windshield adhesive and found that the paint was peeling off from the primer where the glass adhesive attaches to the car. The strength of the paint or clear coat bond to the primer or car metal is not sufficient to hold in the glass as a structural part of the car body. I am a car dealer so have more windshields replaced that a normal person. It is very unusual to see this condition. I am aware that some 2021 Mustang mach e had a recall for this condition but this VIN was not included in that recall. Perhaps it should have been. The glue just peels off with the clear or paint