Ford has initiated a recall of nearly 35,000 electric vehicles, specifically the Mustang Mach-E models from the 2021 and 2022 model years. The recall is prompted by a concern related to a critical component in the propulsion system that may face challenges in handling the heat generated during fast charging or when subjected to rapid consecutive accelerations by drivers.
The issue, as outlined in withdrawal documents released by the National Highway Traffic Safety Administration (NHTSA) on October 13, involves the potential for overheating, leading to the formation of arcs and deformation of electrical contact surfaces. This could result in the failure of the contactor to close properly or welding of components. Ford underscores that such overheating could lead to a loss of power, posing an increased risk of accidents.
This is not the first time Ford has recalled the Mach-E for a similar concern. The previous recall in June 2022 led to a halt in deliveries. As part of that campaign, Ford provided a wireless solution containing revised software for two control modules. For vehicles that received the earlier software solution, Ford notes that, in most cases, the software will proactively detect damage to the contactors and display a warning to the customer.
The prior recall covered nearly 49,000 vehicles. The latest recall impacts a subset of those vehicles, specifically the Mustang Mach-E units equipped with the extended-range battery pack. It involves the physical replacement of the Electric Center Bussed, also known as the High Voltage Battery Junction Box. An updated design for this component went into production on May 22, 2022. However, the potentially faulty part was utilized in production from May 27, 2020, to May 24, 2022, according to Ford.
Ford emphasizes that a failure of the contactor could lead to situations where the vehicle may not start on the next ignition cycle or display a “Stop Safely Now” message, bringing the vehicle to a stop by coasting, even though the power brakes, steering, and accessories will continue to function.
Owners are urged to check if their vehicles are covered by the recall by contacting their local dealerships for further information and potential corrective actions. This proactive measure is aimed at addressing safety concerns and ensuring the continued reliability and performance of the Mustang Mach-E electric vehicles on the road.
