2022 Ford Mustang Mach E engine problems

ENGINE

The high voltage battery junction box connector has failed. There have been two recalls one software and one to replace this part the high voltage battery junction box with a more robust part to handle thermal loads. As of now there are zero recalls on my car open so they are all done. The first time this component failed was around 24k miles ish it's now 56k miles ish and it has failed again even after two recalls and an investigation around the same exact time. This means one of two things has happened either somehow the recalls by Tim Moran ford where not done properly and somehow the older failed part number was installed in my car or the more likely senario is that fords supposed robust part was just a simple part number change without a robust enough design to handle the thermal load. I would like to think that Tim Moran ford who is independent from for has done there due diligence the first time it was replaced and but the correct part number which leads me to conclude the investigation by the NHSTA that resulted in a part change did not fix the issue at hand and the car is now unsafe to drive as this is the second time it has happened to me on this vehicle. Thank god this time I was not going through a curve and headed off road. Same issue almost exact same failure part gone wrong and same issue to date. I demand not only for myself but the safety of others as a former Quality Assurance Representative of electronics on Hueys and Cobras that this be re investigated immediately. It is to late in the game to have zero recalls on my car open two that have been done and the same part fails a second time this should never happen to anyone if it has already been investigated and supposedly fixed. I do not believe it is fixed and the car is not safe to drive I'm hesitant to even go get it when it's ready next week with this serious safety flaw in the design of this vehicle with it still incurring.

NHTSA complaint #11758349 — an unverified report by a vehicle owner.

ENGINE

I am unsure, but I think it's the High Voltage Battery Junction Box. A week after buying the car used from Aaron Ford of Poway, I received a Safely Stop now warning, then the car broke down on the middle of the turning lane into my job a medical clinic putting myself, patients, other drivers, and my coworkers all on danger as it is a busy street. The hazard lights would not work, and the car would not go into neutral. The next day, all the dealership did was replace the 12v battery, then I only got 1 mile from the dealership before it broke down again in an even more busier and dangerous highway in the slow lane and crosswalk. The hazard lights would not work, and the car would not go into neutral.

NHTSA complaint #11757487 — an unverified report by a vehicle owner.

ENGINE

File against: Ford Motor Company Vehicle: 2022 Ford Mustang Mach-E VIN: [XXX] Safety Complaint While driving, the vehicle unexpectedly slowed down, lost power, and became inoperable, creating a serious safety hazard. I was able to pull over safely, but the sudden loss of motive power occurred during active roadway conditions. Dealer diagnosis identified a wiring harness connector failure affecting communication between vehicle control modules. After the repair, the same issue reoccurred within one to two days, again causing loss of power. The vehicle is currently back at the dealership, and the underlying defect has not yet been permanently resolved. This recurring electrical failure represents a loss-of-motive-power safety risk that may indicate a broader wiring harness defect affecting vehicle reliability and safety. Thanks and Regards INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11718385 — an unverified report by a vehicle owner.

ENGINE

- What component or system failed or malfunctioned, and is it available for inspection upon request? According to the technician, there was a 12-volt battery in the beginning, but after staying in the shop for three days, they found that it was HVBJB, also known as the bussed electrical center (BEC). The car was recalled last July and was in the shop for about a month for HVBJB, also known as the bussed electrical center (BEC). The shop had already replaced the part last year. - How was your safety or the safety of others put at risk? The car suddenly stopped and lost battery power when I was driving on [XXX] going to [XXX]. Las Vegas, Nevada. The car turned off, and there was an error message on the screen. I could not move the car anymore. "When the car suddenly stopped, my wife and I felt like we had hit a wall at 45 miles per hour". - Has the problem been reproduced or confirmed by a dealer or independent service center? Yes, last year, it was by Galpin Ford in Los Angeles when the vehicle was called for a recall in that specific part, and now it was by Gaudin Ford in Las Vegas when this incident happened and they claim they need to replace the same part. Recall Reference Number: 23S56 - Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Yes, last year, it was by Galpin Ford in Los Angeles when the vehicle was called for a recall in that specific part, and now it was by Gaudin Ford in Las Vegas when this incident happened and they claim they need to replace the same part. Recall Reference Number: 23S56 - Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11647515 — an unverified report by a vehicle owner.

ENGINE

While driving, the car suddenly stopped, showed a "Stop Safely Now" warning and stopped in the middle of a busy road. Car went into Park and could not be moved from the middle of a busy road. Remained in Park and could not even be shifted into Neutral to be pushed out of the way of bust traffic. Very dangerous. No prior warning. Car had to be towed and now at deal for investigation into cause.

NHTSA complaint #11632408 — an unverified report by a vehicle owner.

ENGINE

Car suddenly lost all power and flashed multiple warnings. Steering also became disabled. This was moving at a low speed through a school zone so it did not cause an accident. After several restart attempts the car moved again but quickly same issue occurred. Car was towed to Ford. Still waiting for diagnostic.

NHTSA complaint #11582479 — an unverified report by a vehicle owner.

ENGINE

Car got a stop safely now error and stopped working. I had to call a tow truck and have it sent to a dealership.

NHTSA complaint #11560528 — an unverified report by a vehicle owner.

ENGINE

Waiting for traffic to move in a busy street. Lights went up pedestrian sounder fault stop safely now and the vehicle wouldnt move. I was panicking my life is in danger im stuck between opposite traffic. So I put on the hazard lights and call two tow trucks and called 911. Next day high voltage warning and powertrain malfunction lights went up service now. I setup first available service which is in one week. Called ford said its okay to drive while waiting for the service. 12/14, warning lights disappeared in the morning but in the afternoon same thing happen lights went up pedestrian sounder fault stop safely now and it just stopped again in the middle of a busy street. I checked recall site there was no recall for this specific vehicle concerning this but others were recalled

NHTSA complaint #11560228 — an unverified report by a vehicle owner.

ENGINE

While driving on Route 1 and attempting to pass another motorist, a flashing red "STOP SAFELY NOW" lit on my dashboard, along with multiple warnings of a "powertrain failure". Thankfully I was near my house and was able to get home. But the FordPass App is saying that I had a high-voltage power malfunction and will need to tow the car to my local dealership. Now I am being told that the high-voltage junction box has failed and needs to be replaced (consistent with Ford Recall notice 23S56). Unfortunately, Ford hasn't produced a replacement part, and after speaking with multiple dealerships, I have been told that an updated replacement part may not be available until Q1 2024 (Or between 6-18 weeks from now). Those of us who purchased these vehicles now have $65K+ paperweights. Ford should buy back these cars, fix them, then resell them through local dealerships. Please help remedy this situation.

NHTSA complaint #11556598 — an unverified report by a vehicle owner.

ENGINE

I bought a 2022 mustang Mach e. Which was supposedly fixed at the factory in regards to the HVBJB issue. However, in mid 2023, my vehicle suffered a limp mode/warning about reduced power while on the interstate, was limited to about 60mph with very poor acceleration. Was diagnosed by ford tech as a failure of the recalled part and required HVBJB and BECM replacement, similar to 22V-412 recall. I think this should be added to RQ23004 investigation, as these vehicles had both the new hardware and software and were supposed to be “fixed”.

NHTSA complaint #11539783 — an unverified report by a vehicle owner.

ENGINE

The HVBJB (high-voltage battery junction box) subassembly in ALL Ford Mach-e vehicles has known defects with insufficiently robust main contactors that are known to fail under normal charging and driving conditions as outlined in NHTSA Campaign Number 22V412000. 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, as well as failure of other 12V systems due to inability to charge the 12V battery properly after contactors are damaged. Less catastrophic results can include failure to start, which can strand drivers and passengers in remote areas, bad weather conditions, and also 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, more robust HVBJB.​ ​ My complaint is that Ford's recall under campaign 22V412000 is a software-only attempt to prevent future damage, and does not require 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 restart 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, more robust parts without a known failure risk.​ Thank you very much for your time.

NHTSA complaint #11510276 — an unverified report by a vehicle owner.

ENGINE

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.

NHTSA complaint #11488714 — an unverified report by a vehicle owner.

ENGINE

THE BATTERY ENERGY CONTROL MODULE RECALL SOFTWARE UPDATE WAS COMPLETED ON MY VEHICLE ON SEPTEMBER 22ND 2022 AT 1203 PM AT GOSCH FORD OF HEMET. UPON LEAVING AROUND A MILE DOWN THE ROAD I WAS DRIVING AROUND A CORNER. WHILE IN THIS CORNER MULTIPLE THINGS HAPPENED AT THE SAME EXACT MOMENT. MY TRACTION LIGHT MOMENTARILY FLASHED ALONG WITH A SERVICE WRENCH. VEHICLE SKID PARTIALLY OFF-ROAD INTO THE DITCH. I LOST CONTROL FOR A BREIF MOMENT BUT WAS ABLE TO GAIN CONTROL BEFORE CRASHING. MY SPEED WAS DRASTICALLY REDUCED TO ABOUT 1/3 OF ITS NORMAL POWER. THE VEHICLE WOULD STILL DRIVE JUST MUCH SLOWER. UPON THIS HAPPENING I IMMEDIATELY TOOK MY VEHICLE BACK TO THE DEALERSHIP. THIS RECALL WAS VERY VAGUE. WHEN I WAS AT THE DEALERSHIP I INITIALLY ASKED THE FORD SERVICE SALESMAN DANIEL VENTURA IF THIS SOFTWARE CHANGED ANY ASPECT OF MY VEHICLES PERFORMANCE. HE THEN READ THE RECALL LETTER AND SAID IF IT DID IT NORMALLY WOULD SAY IT EITHER IN THE RECALL ITSELF OR THE LETTER FORD SENDS YOU THEY WOULD NORMALLYSAY IT IN IT. IT DID NOT MENTION THAT WHILE DRIVING THRU A CORNER IF YOU LOOSE POWER IN THE CAR DUE TO A BATTERY CONTROL MODULE FAILURE THAT YOU MAY LOOSE TRACTION AND LOOSE CONTROL OF THE CAR MOMENTARILY. THIS IS A VERY UNSAFE DRIVING CONDITION. FURTHERMORE WHEN I LEFT THE DEALERSHIP THE CAR DROVE DIFFERENTLY. IT SEEMED LIKE THE HORSE POWER WAS ABOUT 5-10 HP LESS THEN WHEN PURCHASED. IT FELT A LITTLE WEIRD TO GET USED TO DRIVING DOWN THE ROAD SINCE IT HAD A LITTLE BIT MORE PUSH THEN BEFORE. I MENTION THIS BECAUSE I BELIEVE THAT AS A CONSUMER I HAVE A RIGHT TO KNOW THE SOFTWARE THAT IS GOING INTO MY CAR. IF ANY ADVERSE REACTION THAT MAY CAUSE ME A DIFFERENT DRIVING EXPERIENCE OR PUT MY LIFE AT RISK OF CRASHING SHOULD HAVE BEEN INCLUDED IN THE SAFETY RECALL OR THE LETTER FORD HAD SENT US IN THE RECALL. I AM A FIRM BELIEVER THEY DO NOT WANT TO TELL US THAT THIS VEHICLE IS STILL NOT SAFE TO DRIVE AS WHAT HAPPENED TO ME HAVING THE BATTERY CONTROL MODULE FAILURE DURING CORNERING.

NHTSA complaint #11485995 — an unverified report by a vehicle owner.

ENGINE

The High Voltage Battery Junction Box (HVBJB) in ALL Ford Mustang Mach-E vehicles has known defects with faulty 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 High Voltage Battery Junction Box (HVBJB) with a new one. ​ 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 High Voltage Battery Junction Box (HVBJB) with a new one.

NHTSA complaint #11473469 — an unverified report by a vehicle owner.