In a recent development, US auto safety regulators have launched an investigation into Ford Motor’s recall of nearly 49,000 Ford Mustang Mach-E electric vehicles to determine if the recall adequately addressed safety concerns. The investigation will also determine if the recall should be expanded to include more vehicles. The recall was issued by Ford in June 2022 due to potential overheating of high voltage battery main contactors caused by DC fast-charging and repeated wide-open pedal events. This overheating could result in an immediate loss of propulsion power, posing a risk of crashes.
Following the initial recall, Ford issued a technical service bulletin to replace the High Voltage Battery Junction Box in the affected vehicles. The National Highway Traffic Safety Administration (NHTSA) revealed that it has initiated a recall query involving 64,000 Mach-E vehicles after receiving 12 consumer complaints related to vehicles that had received the recall fixes. In response, Ford has stated that it is cooperating with NHTSA in their investigation.
To address the recall, Ford implemented software updates to monitor the temperature of the contactor and reduce battery power, thereby preventing damage to the contactor. The software updates also monitor contactor resistance to identify overheating and reduce vehicle power to prevent further damage. However, one Mach-E owner reported to NHTSA that their vehicle experienced a second catastrophic failure of the High Voltage Battery Junction Box just two days after receiving the software update.
In another incident, a Mach-E driver in Florida stated that shortly after charging at a DC fast charge station, their vehicle displayed a “safely stop now” message on the screen panel and came to a complete stop within seconds while on a highway on-ramp. After waiting for several hours, the driver managed to restart the vehicle and drive for three miles before experiencing another stop.
These incidents highlight the potential challenges and safety concerns associated with the Ford Mustang Mach-E electric vehicles. With the NHTSA investigation underway, it remains to be seen how Ford will address these issues and ensure the safety of its consumers.
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