https://arstechnica.com/cars/2023/08/nhtsa-is-looking-into-a-ford-mustang-mach-e-recall-from-2022/ Skip to main content * Biz & IT * Tech * Science * Policy * Cars * Gaming & Culture * Store * Forums Subscribe [ ] Close Navigate * Store * Subscribe * Videos * Features * Reviews * RSS Feeds * Mobile Site * About Ars * Staff Directory * Contact Us * Advertise with Ars * Reprints Filter by topic * Biz & IT * Tech * Science * Policy * Cars * Gaming & Culture * Store * Forums Settings Front page layout Grid List Site theme light dark Sign in arcing is bad -- Ford's recall of Mustang Mach-Es in 2022 is under investigation by feds There have been 12 complaints of power loss following the software update. Jonathan M. Gitlin - Aug 21, 2023 3:34 pm UTC A Ford Mustang Mach-E seen from the front 3/4 angle Enlarge / Like the FedEx arrow or the elephant in GM's new logo, once you see the bandito mustache, you'll never unsee it. Jonathan Gitlin reader comments 93 with Last year, Ford issued a recall for almost 49,000 Mustang Mach-E crossovers due to a problem with the electric vehicles' high-voltage battery contactors. The automaker's fix was a software update to two control modules on the Mach-E, but on Monday, Reuters reported that the National Highway Traffic Safety Administration's Office of Defects Investigation has opened a recall query to see if Ford's software recall actually did the job. On June 21, 2022, Ford issued a recall for 48,924 Mustang Mach-Es, instructing dealerships to stop delivering the EVs to customers until the software fix was ready. The problem was battery contactors that could overheat during DC fast charging or with repeated use of full throttle; that overheating could lead to either arcing or the contact surfaces deforming, which could lead to a complete loss of power while driving. According to the recall safety notice, Ford had 286 warranty claims for open or welded contactors between July 2021 and May 2022. Ford's fix was a software update to the secondary onboard diagnostic control module and the battery energy control module. The new software didn't fix the contactors, but it does monitor contactor temperature and resistance and can reduce battery power to prevent contactor damage should either of those fall out of range. Ford also issued a technical service bulletin to replace the high-voltage battery junction box in Mach-Es that had been given the new software but still suffered a loss of propulsion due to this defect. Advertisement But NHTSA has received 12 post-recall complaints from Mach-E customers alleging the fix did not work. A Mach-E owner from Sunnyvale, California, reported having to have two high-voltage battery-junction boxes replaced in the span of three months. Another owner reported having a permanent loss of power while driving at 70 mph in Texas. A Mach-E owner in Honolulu, Hawaii, told NHTSA their car lost power, and the steering seized while driving a software-updated Mach-E. "As I was driving to merge onto the freeway 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 had no time to pull my car over since it died immediately," wrote a Mach-E owner from Hercules, California. The most recent complaint cites an incident that happened on June 8, 2023, in Mandeville, Louisiana. In this case, a Mustang Mach-E lost power and died on a busy highway off-ramp. NHTSA's ODI is not the only investigation into the Mach-E battery contactor recall. Last July, three owners sued Ford in federal court over the defect, alleging that Ford's software update was not a "true solution to the battery/overheating issue." Ars contacted Ford for a comment and will update this story as and when it replies. reader comments 93 with Jonathan M. Gitlin Jonathan is the Automotive Editor at Ars Technica. He has a BSc and PhD in Pharmacology. In 2014 he decided to indulge his lifelong passion for the car by leaving the National Human Genome Research Institute and launching Ars Technica's automotive coverage. He lives in Washington, DC. Advertisement Promoted Comments [avatar] EnerJi I didn't see anywhere if this affected newer model years. There was one comment about cars manufactured after a certain date being updated, but I'm more curious about '23s and upcoming '24s. On the plus side I probably wouldn't spring for the GT edition, so less likely to be affected. 23's have the same unit as the 22's built after May 2022. I wonder that the specs of the contactor were and who made them? I'm seeing some newer designs being built this year and I wonder if they will still have these issues. Below is a thread of someone did a tear down with photos and detailed analysis of the original all-wheel drive HVBJB. Very interesting read for anyone interested in some of the gory details behind this part! https://www.macheforum.com/ teardown-and-analysis-of-base-awd-hvbjb-high-voltage-battery-junction-box / August 21, 2023 at 7:33 pm Channel Ars Technica - Previous story Next story - Related Stories Today on Ars * Store * Subscribe * About Us * RSS Feeds * View Mobile Site * Contact Us * Staff * Advertise with us * Reprints Newsletter Signup Join the Ars Orbital Transmission mailing list to get weekly updates delivered to your inbox. Sign me up - CNMN Collection WIRED Media Group (c) 2023 Conde Nast. All rights reserved. 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