2021 FORD MUSTANG MACH E Complaints

When unplugging the vehicle from my home charger a large spark came out of the vehicle receptacle for the charging cable. This started happening a few weeks ago and has happened twice.

I was driving on the freeway at normal speed when my rear passenger window shattered. My son was sitting next to the window when it shattered and had glass shards all over him.

My vehicle was built with under-specked high voltage battery joint assembly bracket. The failure of this connection has caused many incidents whereby the car cannot start, or suddenly stops while driving. The part is either not to original specification or was not designed correctly. In either case, providing a SW fix to simply limit the voltage does not actually prevent or correct the problem. As this fix has rolled out, there are numerous reports of the issue still happening. This is because the fix doesn't fix the original condition, it only serves to limit the scope going forward. But if the part has been in use for 2 years as mine is, then the damage has already occurred and the fix will not prevent my issue. The appropriate fix for the problem is a replacement HVBJB, which Ford is only installing AFTER the incident occurs. This is totally unacceptable and is simply an accident waiting to occur. The SW fix is analogous to the original attempt by GM to correct the Bolt battery fire situation. Eventually, the batteries were replaced, which was the correct response. I am simply demanding that Ford follow a similar path. Consumer stated number for NHTSA Campaign Number: 22V412000.

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.

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

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.?

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 NHTSA Campaign Number 22V412000 (Ford recall notice 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.?

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.

My car had Ford recall campaign software patch 22S41 applied to it on Tuesday June 28, 2022. On Thursday June 30, 2022 (two days later), my car suffered its second catestrophic failure of its High Voltage Battery Junction Box. This failure was the exact safety problem Ford's recall software patch was representing to "fix". My family and I were driving from SF Bay Area to Los Angeles, and the car exhibited a "Service Vehicle Soon" warning while driving on I-5 South at Castic, CA. My power was limited to only 30% of available power, and I drove to a Ford dealer over 2 hours on local roads without turning off the car from the mountains in an attempt to not be stranded catestrophically. My vehicle is currently having its contactors replaced for a second time in less than 3 months, this time with a different revised part from Ford that has higher engineering tolerances. Ford refuses to offer this part to current owners of the Mach-E, and is awaiting owners to have their vehicles fail catestrophically like mine before providing access under warranty to a part that fixes their serious safety defect. New Mach-Es are produced in the factory with the revised contactors, which Ford would probably not do were the software patch it provides to current owners sufficient to address the safety issue.

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