The United States auto safety agency has initiated an investigation into Ford Motor’s 2022 recall of approximately 49,000 Ford Mustang Mach-E electric vehicles. The regulators are examining whether the recall adequately addressed concerns and whether it should be extended to encompass a wider range of vehicles.
Ford had issued the recall in June 2022 due to concerns that the high voltage battery main contactors in the Mach-E EVs could overheat during DC fast-charging and repeated wide-open pedal events. This overheating could lead to an immediate loss of propulsion power, thereby increasing the risk of a potential crash.
Following the recall for vehicles from the 2021 and 2022 model years, Ford had also released a technical service bulletin, which detailed the replacement of the High Voltage Battery Junction Box in the affected vehicles.
The National Highway Traffic Safety Administration (NHTSA) has now launched an inquiry into approximately 64,000 Mach-E vehicles. This move comes after the agency received a total of 12 consumer complaints involving vehicles that had undergone the recall fixes.
In response to the investigation, Ford stated that it is actively collaborating with the NHTSA to assist in their examination.
Ford’s initial recall resolution centered on implementing software updates aimed at monitoring contactor temperature and reducing battery power. These measures were intended to prevent damage to the contactor. Additionally, the updates aimed to monitor contactor resistance, thereby identifying any instances of overheating and subsequently decreasing vehicle power to avoid further damage.
A Mach-E owner shared their experience with the NHTSA, revealing that shortly after the software update, their vehicle encountered a second significant failure of its High Voltage Battery Junction Box. The incident occurred just two days after the update was installed. The vehicle exhibited a “Service Vehicle Soon” warning, and its power was limited to only 30% until reaching a dealership, during a drive from the San Francisco Bay Area to Los Angeles.
Another Mach-E driver in Florida recounted an incident where, following a charge at a DC fast charge station, the car’s screen panel displayed a “safely stop now” message. Consequently, the vehicle came to a sudden halt within seconds on a highway on-ramp. After several hours had passed, the driver managed to restart the vehicle. However, they were only able to travel three miles before the car came to another stop.