Whether you’ve heard about it on the news or you received a letter from the automotive manufacturer, a motor vehicle recall is something you’re most likely familiar with.
All man-made products are subject to a trial and development procedure. Sometimes, the problems will only occur once a product has been manufactured, shipped, and sold.
A vehicle recall occurs when a car manufacturer deems a specific model or make a safety hazard. The automaker often offers free repair services to remedy the issue.
In the past decade, nearly 300 million recalls have been announced by different automakers worldwide. Your car may be included in at least one of these recalls, specifically if you own or lease a Ford.
If such were true, you might wonder what to do if your Ford vehicle, particularly the Ford Mach E electric SUV (sport utility vehicle), is part of a recently announced recall.
This write-up explores these topics and provides valuable information about potential issues of the coveted electric car. Moreover, this article will answer frequently asked questions about the ins and outs of a recall procedure.
For more information and legal assistance about vehicle recalls, visit and read through our website, LemonLawLawyers.org. Don’t let a lemon car compromise your driving experience.
Is Ford Recalling 35,000 US Mach-E EV?
In October 2023, Ford Motor Company recalled approximately 35,000 Mustang Mach E vehicles due to a battery issue. The high-voltage main contactors of the battery may overheat, resulting in a loss of motive power.
This recall is a follow-up to Ford’s previous June 2022 recall of over 48,000 Mach-E electric vehicles (EVs) due to the same issue. For the original recall, the offered fix was to update the vehicle’s software system.
For this most recent recall, Ford Motor Company issued a service bulletin to replace the battery junction box. The automaker also mentioned that it is aware of the reported instances of driving power loss after completing the 2022 recall.
But before further exploring the various issues that caused the Ford Mach E recalls, let’s first look at some of the model’s highlights.
The 2022 Mustang Mach-E offers options with a standard-range 70-kWh battery or an extended-range 91-kWh pack. These power an electric motor at the rear or both axles, creating all-wheel drive on certain models.
The GT and GT Performance models boast 480 horsepower and up to 634 pound-feet of torque. Meanwhile, the GT Performance hit 60mph in 3.7 seconds.
Less powerful models range from 266 to 346 horses and 317 to 428 pound-feet. The Mach-E rolls on 18- to 20-inch wheels and can be equipped with adaptive dampers for customizable ride firmness.
The 2022 Mach-E offers an Environmental Protection Agency (EPA)-estimated range between 211 and 305 miles, depending on the motor type and battery pack, which doesn’t quite match the top-range Teslas. All models support fast charging, though.
The standard Ford mobile charger included with every Mach-E adds up to 30 miles of range per night with a 120-volt outlet or up to 80% battery life overnight with a 240-volt outlet.
A Ford charge station can be ordered and installed by certified electricians for faster charging, delivering 32 miles per hour and overnight battery recharge.
The Mach-E’s battery placement beneath the floor maximizes cargo and passenger space. Unlike the regular Mustang, the Mach-E’s interior is distinct, featuring a sleek digital gauge cluster on the streamlined dashboard and a large vertically mounted touchscreen.
The center console sports a floating, flip-up armrest, handy for storing items between front-seat passengers. Some other features include heated front seats, customizable ambient interior lighting, a heated steering wheel, wireless charging, and a panoramic sunroof.
The front trunk’s durable plastics allow easy cleaning and accommodate ice and messy items. The Mach-E boasts 29 cubic feet of cargo space behind the rear seats, extendable to 60 cubic feet if the rear seats are folded.
Which Vehicles Are Affected?
The vehicles affected by the overheating battery system recall are specific 2021 to 2022 model year Ford Mustang Mach E extended-range and GT vehicles built between May 27, 2020, and May 24, 2022.
What Is the Issue Tied to This Safety Recall?
Repeated wide-open pedal events and DC (direct current) fast charging can cause the high-voltage battery contactors to overheat on some GT and extended-range Ford Mach E vehicles.
Overheating may cause deformation of the contact surfaces, leading to a contactor that doesn’t close correctly or one that welds closed. An improperly closed, overheated contactor may result in losing driving power.
What Is the Cause of the Issue?
The culprit for the Ford Mustang Mach E’s overheating battery system issue is the incapacity of the high-voltage battery main contactor to handle heat generated by multiple wide-open-pedal DC fast-charge events.
The damages caused by the wear before the software update remedy may compromise the software’s performance and effectiveness.
What Is the Expected Repair?
Once recall remedy parts become available, you may bring your vehicle to a local Ford dealer and have the high-voltage battery junction box replaced. This repair is free of charge.
Ford Mustang Mach E Recall Repair Investigation
Ford Motor Company became aware of the power failure issues and announced a recall in June 2022, affecting approximately 48,000 Mach-E electric cars. This recall followed warranty claims that involved overheated contactors.
The NHTSA (National Highway Traffic Safety Administration) warned that the battery issues could translate to immediate driving power loss, leading to the driver losing control of the car and increasing the risk of an accident.
As stated, Ford rectified the issue by providing diagnostic and battery energy control module software updates that aim to monitor the contactor’s temperature, reduce battery power, and identify potential overheating.
Following the recall-related repairs, federal safety officials launched an investigation to determine whether the performed repairs were satisfactory after the NHTSA received reports from drivers who continued to experience the issue with their vehicles.
Mustang Mach-Es and GTs With Extended Range Batteries Recalled Because Full-Throttle Acceleration Can Melt Welds and Cause Power Loss
According to a filing by the NHTSA, the battery problem of the Ford Mach E electric vehicle stems from its high-voltage battery main contactors. The components of these contactors are prone to overheating, causing the device to get welded closed or lose its ability overall.
In other words, whether you’re simply driving or using the fast charge function, there’s a chance you’ll put a strain on your vehicle that could lead to a significant accident.
2022 Ford Mustang Mach E Recalls
Before discussing the 2022 safety recalls for the Ford Mustang Mach E, let’s first look at some notable recalls for other Ford models.
Per a filing by the NHTSA, some of the Ford vehicles that have been part of a safety recall in recent years are the Ford F-150, Edge, Explorer, Fusion, Escape, and Mustang.
Since the Ford F-series pickups have had a significant market share for years, their recall chances are relatively higher than other models.
About 2 million Ford F-150 Regular and SuperCrew pickups were recalled due to their seatbelt pre-tensioners that can ignite a fire.
Additionally, Ford recalled approximately 350,000 F-150, Expedition, and F-750 vehicles due to an unseated gear shift cable clip that may not properly secure the gear shift.
A similar issue caused the safety recall of about 550,000 Ford Fusion and Escape vehicles, where a bushing problem may cause the vehicle to move even though the transmission indicates it is in park mode.
In 2016, specific Ford truck models were also recalled because of a malfunctioning diesel fuel system. The protective shield on the truck’s fuel module can dislodge and cause a leak.
Certain 2016 to 2017 models of Ford Edge vehicles were also recalled due to their airbags not working as intended. As of 2018, this recall’s completion rate was 81.4%.
Finally, according to the NHTSA, there are four Ford Mustang Mach E recalls as of December 2023. The reasons for these recalls are the following:
- Overheated high-voltage battery contactor
- Axle shaft issues
- Seatbelt buckle issues
Electrical System: Propulsion System: Traction Battery: Management System/Energy Control Module (BMS/BECM): Software
Some 2021 to 2020 Ford Mustang Mach E vehicles with an extended range battery were recalled in October 2023 due to an issue with their battery contactors.
The table below highlights the specifics of the safety recall.
| Issue | Remedy | Reference Number |
| • An overheated contactor can result in driving power loss, increasing the possibility of a crash. | • Ford replaced the bussed electrical center (BEC) or the high-voltage battery junction box (HVBJB). • Vehicles repaired under the previous recall 22V-412 must undergo the new recall remedy. | • 23S56 |
For the previous recall in June 2022, the remedy was to update the on-board software.
Powertrain: Axle Assembly: Axle Shaft
In September 2022, Ford Motor Company recalled certain 2022 Mustang Mach E vehicle units due to a problem with their right-rear axle half-shafts.
| Issue | Remedy | Reference Number |
| • The right-rear axle half-shafts may have been manufactured improperly, resulting in the breakage of the half-shaft stem under load. • A faulty half-shaft can cause driving power loss or a rollaway if the vehicle is parked and the electronic parking brake is not activated. • Both of these instances increase the likelihood of a crash. | • Ford dealers inspected the vehicle’s serial number and replaced the right-rear half-shaft. | • 22S55 |
Owner notification letters for this recall were mailed in September 2022.
Seat Belts: Rear/Other: Anchorage
In January 2022, Ford Motor Company issued a safety recall for some 2022 Maverick and 2021-2022 Mustang Mach-E cars due to a potential issue with their seatbelts.
| Issue | Remedy | Reference Number |
| • The rear seat belt buckles may be incorrectly attached to the floor assembly. • As such, these vehicles fail to adhere to the requirements of Federal Motor Vehicle Safety Standards of “Seat Belt Assembly Anchorages” and “Occupant Crash Protection.” | • Ford dealers repaired the rear seat belt buckle attachments. | • 21C36 |
FAQs (Frequently Asked Questions)
What are you doing to take care of customers?
Ford Motor Company addressed the recall of the Ford Mach-E battery issue by providing vehicle rentals and Ford Delivery and Pickup services.
Is Ford aware of any injuries or accidents resulting from this condition?
No. As of December 2023, Ford is unaware of any accidents or injuries resulting from the Ford Mach E battery problem.
Is there anything a customer can do to reduce the chance of the contactor overheating until their vehicle is repaired?
Until remedy parts are available, Ford recommends limiting repeated use of wide-open-pedal accelerations and using the car’s DC fast charge functionality only when necessary.
Are there warning signs that Ford Mach E owners should be aware of?
For vehicles that were repaired and received the software update under the original recall, the software will most likely proactively identify the damage to contactors and display a warning signal.
Meanwhile, the vehicle’s operation would have no immediate effect if the contactors were welded close during driving. However, a warning wrench light will be illuminated upon the next key cycle, and the car will not start.
If the contactors do not properly close while driving, a warning light will also show, and the vehicle will display a “Stop Safely Now” message. The car will also immediately lose driving power in such a case.
When this happens, the car will stop, and all low-voltage systems, such as the steering system, lights, and power brakes, will remain operational.
When will you notify customers of the safety recall?
Ford began sending owner notification letters for this safety recall in November 2023. Alternatively, you can verify if your vehicle is included in the safety recall by entering the VIN (vehicle identification number) on the Ford website.
Usually, Ford vehicles will have their VIN on a metal tag behind the steering wheel and above the instrument panel.
The VIN can also be found on vehicle registration or insurance policy documents. For some car models, the VIN can be found on a tag on the driver-side door.
Will there be a charge to customers?
Spare parts and repair services for Ford recalls are free through a local dealership.
Your vehicle’s recall-related repairs do not necessarily have to be performed at a dealership.
However, suppose you wish to get the free services and include your vehicle in the Ford recall campaign. In that case, the recall-related repair must be done at a dealership registered with your car’s manufacturer.
What is the Ford reference number for this safety recall?
Ford’s reference number for the battery issue safety recall is 23S56.
References
- Ford Recalls
https://www.ford.com/support/recalls/ - NHTSA safety recall results
https://www.cars.com/research/ford/recalls/ - NHTSA
https://www.nhtsa.gov/ - Ford website
https://www.ford.com/ - Ford Mach E
https://www.ford.com/suvs/mach-e/
Images sourced from Ford Media Center.