NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
18 reportsClear category filterMileage unknown · Aug 19, 2026
Fuel/propulsion SystemUnknown Or Other
I was pulling into a parking lot at low speed when the car suddenly began accelerating rapidly on its own. Fortunately, when I hit the brakes it stopped without incident. However, if someone had been right in front of me at the time - a pedestrian or car - it could have resulted in a crash. I am certain that I didn't hit the …
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I was pulling into a parking lot at low speed when the car suddenly began accelerating rapidly on its own. Fortunately, when I hit the brakes it stopped without incident. However, if someone had been right in front of me at the time - a pedestrian or car - it could have resulted in a crash. I am certain that I didn't hit the accelerator, nor was it pushed by floor mats or anything like that. It is conceivable that when I was turning, my left palm activated the cruise control in some manner, but that scenario wouldn't explain the acceleration part. And frankly, I don't think that is what happened. I love the vehicle and am not trying to get anything out of it. I am a capable driver with good reflexes and experience. I was able to stop it, but if this were to happen to a new driver or senior driver it could result in a crash. I looked on reddit and many others report exact same issues.
NHTSA ODI #11757918
Mileage unknown · Jul 8, 2025
Fuel/propulsion SystemPower Train
I was driving my car when all of a sudden it lost all acceleration and power, I was lucky that I wasn't on the highway anymore and was able to pull over safely on a side street while car was rolling still. Dealer said 12V battery fused, and I have been reading forums where this is a common issue.. In a normal ICE car when 12V b…
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I was driving my car when all of a sudden it lost all acceleration and power, I was lucky that I wasn't on the highway anymore and was able to pull over safely on a side street while car was rolling still. Dealer said 12V battery fused, and I have been reading forums where this is a common issue.. In a normal ICE car when 12V battery dies while driving, car can still drive, in this case, it just stops and pops up a dozen errors about everything being broken.
NHTSA ODI #11671895
Mileage unknown · Oct 24, 2024
Electrical SystemFuel/propulsion System
Ford knowingly sold unsafe vehicles. NHTSA caught them and forced a recall on the High Voltage Junction Box (they are still failing, so you may want to look into this). But what they have hidden from you and all of it's customers that they suckered in buying their defective product, is that the front motors, have undersized wiri…
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Ford knowingly sold unsafe vehicles. NHTSA caught them and forced a recall on the High Voltage Junction Box (they are still failing, so you may want to look into this). But what they have hidden from you and all of it's customers that they suckered in buying their defective product, is that the front motors, have undersized wiring, which could cause a fire . They have attempted to hide this from the public, by limiting the power of the car to 5 seconds of full power and then dramatically decreases the power after that. The sold the cars to consumers without revealing that fact, so folks bought the performance "GT" versions and yet they are neutered. It's only a matter of time, where those tiny wires in the front motors give up and start causing fires. It's time for the government to stand up for he consumer here. I've brought it to [XXX] 's attention, but they are hoping we all go away and allow them to get away with selling a defective potentially dangerous vehicle INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11621808
Mileage unknown · Jul 29, 2024
Fuel/propulsion SystemPower Train
Just towed to Ford dealer. When car was in Drive mode, would go in Reverse. I have video and posted it to the Ford Facebook page.
NHTSA ODI #11605147
Mileage unknown · Apr 25, 2024
Electrical SystemFuel/propulsion System
- What component or system failed or malfunctioned, and is it available for inspection upon request? According to Ford Service, this is confirmed to be a High Voltage Battery Junction Box failure (HVBJB). The part is pending replacement currently at Central Ford, CA. While Ford issue recall (23S56) to replace all HVBJBs in Exten…
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- What component or system failed or malfunctioned, and is it available for inspection upon request? According to Ford Service, this is confirmed to be a High Voltage Battery Junction Box failure (HVBJB). The part is pending replacement currently at Central Ford, CA. While Ford issue recall (23S56) to replace all HVBJBs in Extended Range and GT model '21 and '22 vehicles built before May 24, 2022, my car was built after the date. - How was your safety or the safety of others put at risk? The failure of HVBJB directly leads to the lose of power suddenly when driving on the highway. I was cruising on california state highway CA-110 while the car pops up "stop safely now" on the instrument cluster. I lost all power for acceleration and relies purely on 12V battery to power the accesories. There was no emergency lane near the location of the incident which leads to the blockage of highway on the junction from CA-110S to I-10W. This post a significant threat to me as the driver and all other drivers on highway. More importantly, the 12V almost died before the tow truck and police could arrive to solve the incident. Fortunately, I was not hit by ongoing vehicles, but multiple vehicles have to brake agressively to prevent collision. The car was unable to be shifted to N or D since the incident. -Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? The vehicle had been inspected by Service department at Central Ford and confirmed by engineers at Ford to be a HVBJB failure. - Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? 2 warnings and notifications can be seen from information cluster: "Full accessory power active", and "Stop safely now." There is no information displayed on the main infotainment screen.
NHTSA ODI #11585336
Mileage unknown · Apr 11, 2024
Electrical SystemEngineFuel/propulsion System
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 ODI #11582479
Mileage unknown · Dec 17, 2023
Electrical SystemEngineFuel/propulsion System
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 ODI #11560528
Mileage unknown · Nov 6, 2023
Electrical SystemFuel/propulsion SystemPower Train
On November 18, 2022 my vehicle's High Voltage Battery Junction Box (HVBJB) failed. Ford replaced this part with an "upgraded" version of this part and I received my car back on November 28th. Shortly thereafter, the NHTSA issued a recall, the solution for which was a software update that my car received. On October 10, 2023 m…
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On November 18, 2022 my vehicle's High Voltage Battery Junction Box (HVBJB) failed. Ford replaced this part with an "upgraded" version of this part and I received my car back on November 28th. Shortly thereafter, the NHTSA issued a recall, the solution for which was a software update that my car received. On October 10, 2023 my vehicle's HVBJB failed once again (the newer upgraded part). Coincidentally, while my car was in the shop, the NHTSA issued a second recall for this issue, indicating that Ford would be recalling the physical HVBJB. Shortly after this recall, my recall was marked as complete because I received the upgraded version of the part once again. Ford's upgraded part that is a solution to this issue has been issued in many Mach-e cars and is the standard for late '22 models and '23 models; however, in addition to my own HVBJB failing, I am hearing many instances of this newer part failing. Being that this recall stemmed from vehicles potentially losing propulsion as a result of this failure, the risk still exists (although potentially at a lower rate). I do, however, believe that Ford knows that this failure rate is still high and that their upgraded part does not provide a sufficient solution to the problem but has not been transparent with the NHTSA due to the costs associated with redesigning a third version of this part. I do not feel safe driving my family in this car because I know that it's just a matter of time before this part fails once again.
NHTSA ODI #11553856
Mileage unknown · Sep 28, 2023
Electrical SystemFuel/propulsion SystemPower Train
The high voltage battery junction box failed on my car at 9500 miles, and now again at 19200 miles. Failure prevents the car from running properly, or at all. The dealership is reporting that Ford has not developed an updated replacement part, and is only replacing with the same part that the vehicle left the factory with.
NHTSA ODI #11547152
Mileage unknown · Sep 8, 2023
Electrical SystemFuel/propulsion SystemUnknown Or Other
While driving the vehicle in the highway the service/malfunction indicator light (MIL, wrench symbol) turned on and the vehicle dramatically lost propulsion power limiting my acceleration/speed. I opened the Ford Pass App on my phone and the following messages were shown regarding the issue: "High-Voltage Battery Warning and Pow…
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While driving the vehicle in the highway the service/malfunction indicator light (MIL, wrench symbol) turned on and the vehicle dramatically lost propulsion power limiting my acceleration/speed. I opened the Ford Pass App on my phone and the following messages were shown regarding the issue: "High-Voltage Battery Warning and Powertrain Malfunction/Reduce Power". The message in the app also indicated to contact the dealer immediately. I would estimate that max acceleration was instantly reduced over 30%, causing a great concern while cruising at highway speeds. Previous to the date of this incident, the warning/check engine light never turned on. I made the next exit to use secondary roads as a precautionary measure since the max acceleration was limited. I am very active in various Mach-E forums, and this is a well-known issue for Ford. These messages are the ones related to a potential design problem with the High Voltage Battery Junction Box (HVBJB) included in my vehicle (Mach-Es built on or before May 28, 2023). My production date was January 2022. This vehicle got the safety recall #22S41 (software update) at the dealer last year. The software basically allowed the driver to get these warning messages if issues with the HVBJB contactors were detected. It is noteworthy to mention that I did not get the “Stop Safely Now” message, which would have made the vehicle undrivable. Next morning the wrench symbol disappeared from my instrument cluster. Ford issued a technical service bulletin #23-2257 to address a fix, which will involve the replacement of the potentially defective HVBJB for a redesigned one. The dealer indicated the remedy Ford provided was the software update, however multiple owners have reported the replacement of the potential defective part by Ford can only be done if the vehicle is totally inoperable showing the "Stop Safely Now" message. A sudden loss of propulsion while cruising at highway speeds is a safety concern for driver and others.
NHTSA ODI #11543466
Official recalls
9Jun 30, 2026
Ford Motor Company (Ford) is recalling certain 2021-2023 Mustang Mach E vehicles. The rear differential pinion shaft may fracture.
Consequence & remedy
Consequence: Differential pinion shaft fracture may result in a loss of drive power, or unintended vehicle movement if the vehicle is in park without the parking brake applied, increasing the risk of a crash.
Remedy: Dealers will repair or replace the rear differential assembly as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed July 13, 2026. Additional letters will be sent once the remedy is available, anticipated in late December 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S50.
Jun 27, 2025
Ford Motor Company (Ford) is recalling certain 2022 Mustang Mach E vehicles equipped with an extended range battery. The high voltage battery main contactors may overheat.
Consequence & remedy
Consequence: An overheated high voltage battery contactor can result in a loss of drive power, increasing the risk of a crash.
Remedy: Dealers will replace the high voltage battery junction box, free of charge. Owner notification letters were mailed July 10, 2025. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 23S56. This recall is an expansion of previous NHTSA recall number 23V687.
Jun 13, 2025
Ford Motor Company (Ford) is recalling certain 2021-2025 Mustang Mach E vehicles. In the event of a low battery charge, the electronic door latches may remain locked once the driver or front passenger exits and shuts the door, possibly trapping someone who is unable to use the inside door release handles, such as a child in the back seat.
Consequence & remedy
Consequence: The inability to enter or exit the vehicle in an emergency increases the risk of injury.
Remedy: Dealers will update the Powertrain Control Module (PCM) and the Secondary On-Board Diagnostic Control Module C (SOBDMC) software, free of charge. Owner notification letters were mailed to 2021-2025 Mustang Mach-E owners September 12, 2025. Additionally, Owner notification letters were mailed to 2024-2025 Mustang Mach-E owners July 10, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S65.
Additional source detail variants (2)
Electrical System:body Control Module:software
Ford Motor Company (Ford) is recalling certain 2021-2025 Mustang Mach E vehicles. In the event of a low battery charge, the electronic door latches may remain locked once the driver or front passenger exits and shuts the door, possibly trapping someone who is unable to use the inside door release handles, such as a child in the back seat.
Consequence: The inability to enter or exit the vehicle in an emergency increases the risk of injury.
Remedy: Dealers will update the Powertrain Control Module (PCM) and the Secondary On-Board Diagnostic Control Module C (SOBDMC) software, free of charge. Owner notification letters were mailed to 2021-2025 Mustang Mach-E owners September 12, 2025. Additionally, Owner notification letters were mailed to 2024-2025 Mustang Mach-E owners July 10, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S65.
Latches/locks/linkages:doors:latch
Ford Motor Company (Ford) is recalling certain 2021-2025 Mustang Mach E vehicles. In the event of a low battery charge, the electronic door latches may remain locked once the driver or front passenger exits and shuts the door, possibly trapping someone who is unable to use the inside door release handles, such as a child in the back seat.
Consequence: The inability to enter or exit the vehicle in an emergency increases the risk of injury.
Remedy: Dealers will update the Powertrain Control Module (PCM) and the Secondary On-Board Diagnostic Control Module C (SOBDMC) software, free of charge. Owner notification letters were mailed to 2021-2025 Mustang Mach-E owners September 12, 2025. Additionally, Owner notification letters were mailed to 2024-2025 Mustang Mach-E owners July 10, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S65.
May 9, 2025
Ford Motor Company (Ford) is recalling certain 2021-2024 Bronco, F-150, 2021-2024 Edge, 2022-2025 Escape, F-250, F-350, F-450, F-550, F-600, 2022-2024 Expedition, 2022-2025 Transit, 2021-2023 Mach-E, 2024 Ranger, Mustang, 2021-2023 Lincoln Nautilus, 2022-2024 Navigator, and 2023-2024 Corsair vehicles. A software error may cause the rearview camera image to delay, freeze, or not display when the vehicle is in reverse.
Consequence & remedy
Consequence: A frozen or missing rearview camera image can reduce the driver's view behind the vehicle, increasing the risk of a crash.
Remedy: The accessory protocol interface module (APIM) software will be updated by a dealer or through an over-the-air update, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model and model years. Interim letters notifying owners of the safety risk were mailed on June 26, 2025. Additional letters will be mailed once the final remedy is available on each phase. Owner notification letters were sent on October 8, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S49.
Feb 28, 2025
Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang Mach-E vehicles previously repaired incorrectly under recall number 22V-412. The high voltage battery main contactors may overheat.
Consequence & remedy
Consequence: An overheated high voltage battery contactor may cause the vehicle to lose drive power, increasing the risk of a crash.
Remedy: Dealers will update the on-board software, free of charge. Owner notification letters were mailed April 11, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S14.
Oct 13, 2023
Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang Mach-E vehicles equipped with an extended range battery. The high voltage battery main contactors may overheat.
Consequence & remedy
Consequence: An overheated high voltage battery contactor can result in a loss of drive power, increasing the risk of a crash.
Remedy: Dealers will replace the high voltage battery junction box, free of charge. Owner notification letters were mailed December 29, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S56. Vehicles included in this recall that were previously repaired under recall 22V-412 will need to have the new remedy completed.
Aug 26, 2022
Ford Motor Company (Ford) is recalling certain 2022 Mustang Mach-E vehicles. The right-rear axle half shafts may have been manufactured improperly, allowing the half shaft stem to break under load.
Consequence & remedy
Consequence: A broken half shaft can cause a loss of drive power, or a rollaway could occur while parked if the electronic parking brake is not engaged. Either of these scenarios can increase the risk of a crash.
Remedy: Dealers will inspect the serial number, and replace the right-rear half shaft, as necessary, free of charge. Owner notification letters were mailed September 19, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S55.
Jun 10, 2022
Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang Mach-E vehicles. The high voltage battery main contactors may overheat.
Consequence & remedy
Consequence: An overheated high voltage battery contactor may cause the vehicle to lose drive power, increasing the risk of a crash.
Remedy: Dealers will update the on-board software, free of charge. Owner notification letters were mailed on July 8, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S41.
Dec 16, 2021
Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang Mach-E and 2022 Maverick vehicles. The rear seat belt buckles may not be properly attached to the rear floor assembly. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 208, "Occupant Crash Protection," and 210, "Seat Belt Assembly Anchorages."
Consequence & remedy
Consequence: Improperly attached seat belts may not adequately restrain an occupant in a crash, increasing the risk of injury.
Remedy: Dealers will repair the rear seat belt buckle attachments, free of charge. Owner notification letters were mailed January 28, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C36.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4EA25001 · Collisions Involving Ford Bluecruise
Opened Jan 17, 2025 · No close date supplied
Status: open (inferred from source dates) · Electrical System:adas
On April 25, 2024, NHTSA’s Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE24012) to assess BlueCruise, a partial driving automation system available on certain vehicles manufactured by Ford Motor Company (Ford). NHTSA opened the investigation after the agency received notice of two fatal collisions involving BlueCruise-equipped Ford Mustang Mach-E vehicles. Based on the incidents, NHTSA scoped the investigation to 2021-2024 Mustang Mach-E vehicles equipped with BlueCruise. In June 2024, ODI sent an Information Request (IR) letter to Ford requiring that it provide certain information pertaining to crashes, non-crash reports, and technical specifications that relate to BlueCruise, as well as other Ford partial driving automation systems that offer lane and speed maintenance. In its response to ODI’s IR, Ford stated that there are 2,539,962 Ford and Lincoln vehicles (including subject and peer vehicles) equipped with a partial driving automation system within the scope of the request. The majority of these vehicles are equipped with a system that Ford calls Lane Centering Assist (LCA), which is a hands-on partial driving automation system that combines longitudinal control authority governed by Adaptive Cruise Control (ACC) and lateral control authority governed by a steerable path. LCA is offered on a wide range of Ford and Lincoln models beginning in model year 2019. Vehicles that are equipped with BlueCruise, the focus of this investigation, have LCA capability and additionally offer hands-free partial driving automation when certain conditions are met. Hands-free BlueCruise operation is only offered on certain roadways and system availability is geofenced using vehicle GPS. BlueCruise-equipped vehicles employ a camera-based driver monitoring system to determine driver attentiveness to the roadway. BlueCruise was introduced in model year 2021 and is currently available in a select range of Ford and Lincoln vehicles. For BlueCruise- and LCA-equipped vehicles, both ACC and Pre-Collision Assist (PCA) features use a combination of camera and radar sensing technologies to detect and classify objects. ACC is specifically designed to detect vehicles (including cars, trucks, and motorcycles) and bicycles in front of the subject vehicle which are either stationary or moving in the same direction as the subject vehicle. Through this investigation, limitations in the detection of stationary vehicles in certain conditions have been identified. Specifically, due to the potential for false detection of stationary objects at long distances, Ford designed ACC to inhibit any response to reported stationary objects when the subject vehicle’s approach speed is at or above 62 mph. Additionally, system performance may be limited when there is poor visibility due to insufficient illumination. In addition to reviewing Ford’s response to ODI’s IR, the agency conducted a review of crash and non-crash reports identified collectively through Ford’s IR response, incident reporting through Standing General Order 2021-01 (SGO), and NHTSA vehicle owner questionnaires. In total, 32 crashes and 2,004 non-crash reports on subject and peer Ford vehicles were identified across manufacturer and ODI data sources. A detailed analysis of each crash was conducted including the review of any available police reports, photographs, data recovered from in-vehicle event data recorders, connected vehicle data, and/or other information. In both fatal collisions referenced in the PE24012 opening resume, the subject Ford Mustang Mach-E vehicle was traveling over 70 mph on a controlled-access highway during nighttime lighting conditions with hands-free BlueCruise engaged when it collided with a stationary vehicle. Analysis of data imaged from the vehicles’ event data recorders demonstrates that in each incident, the driver did not apply the brakes or take evasive steering action, and no deceleration was initiated by either the BlueCruise system or PCA prior to impact. Through the agency’s crash analysis, four additional frontal collisions were identified where the subject Ford impacted a stopped or slow-moving lead vehicle or another stationary object located in the travel lane. Two of these four incidents involved BlueCruise-equipped Ford Mustang Mach-E vehicles (included in the failure report summary along with the fatal collisions discussed above), while the other two involved other Ford models equipped with the LCA system. Additionally, a trend was identified through analysis of the non-crash reports relating to allegations that ACC (the longitudinal component of both BlueCruise and LCA) failed to detect and/or respond to a stopped or slow-moving lead vehicle. In these reports, consumers often describe that the absence of deceleration initiated by ACC was unexpected and required harsh manual braking or intervention from the PCA to avoid a frontal collision with the lead vehicle. Based on NHTSA’s analysis, system limitations relating to the detection of stationary vehicles while traveling at highway speeds and in nighttime lighting conditions appear to be factors in collisions under investigation and several apparently similar near-miss, non-crash reports. This Engineering Analysis (EA) is being opened to further investigate these system limitations and to evaluate drivers’ ability to respond to scenarios that exceed system limitations. During the EA, the agency expects to, among other things, perform vehicle evaluations, review additional technical information, and perform additional analysis of related crashes and non-crash reports. The crashes included in the failure report summary can be found at NHTSA.gov under the following SGO report identification numbers: 502-7268, 502-7426, 502-6852, 502-8738.
PE24012 · Collisions Involving Ford Bluecruise
Opened Apr 25, 2024 · Closed Jan 17, 2025
Status: closed (inferred from source dates) · Electrical System:adas
On April 25, 2024, NHTSA’s Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE24012) to assess BlueCruise, a partial driving automation system available on certain vehicles manufactured by Ford Motor Company (Ford). NHTSA opened the investigation after the agency received notice of two fatal collisions involving BlueCruise-equipped Ford Mustang Mach-E vehicles. Based on the incidents, NHTSA scoped the investigation to 2021-2024 Mustang Mach-E vehicles equipped with BlueCruise. In June 2024, ODI sent an Information Request (IR) letter to Ford requiring that it provide certain information pertaining to crashes, non-crash reports, and technical specifications that relate to BlueCruise, as well as other Ford partial driving automation systems that offer lane and speed maintenance. In its response to ODI’s IR, Ford stated that there are 2,539,962 Ford and Lincoln vehicles (including subject and peer vehicles) equipped with a partial driving automation system within the scope of the request. The majority of these vehicles are equipped with a system that Ford calls Lane Centering Assist (LCA), which is a hands-on partial driving automation system that combines longitudinal control authority governed by Adaptive Cruise Control (ACC) and lateral control authority governed by a steerable path. LCA is offered on a wide range of Ford and Lincoln models beginning in model year 2019. Vehicles that are equipped with BlueCruise, the focus of this investigation, have LCA capability and additionally offer hands-free partial driving automation when certain conditions are met. Hands-free BlueCruise operation is only offered on certain roadways and system availability is geofenced using vehicle GPS. BlueCruise-equipped vehicles employ a camera-based driver monitoring system to determine driver attentiveness to the roadway. BlueCruise was introduced in model year 2021 and is currently available in a select range of Ford and Lincoln vehicles. For BlueCruise- and LCA-equipped vehicles, both ACC and Pre-Collision Assist (PCA) features use a combination of camera and radar sensing technologies to detect and classify objects. ACC is specifically designed to detect vehicles (including cars, trucks, and motorcycles) and bicycles in front of the subject vehicle which are either stationary or moving in the same direction as the subject vehicle. Through this investigation, limitations in the detection of stationary vehicles in certain conditions have been identified. Specifically, due to the potential for false detection of stationary objects at long distances, Ford designed ACC to inhibit any response to reported stationary objects when the subject vehicle’s approach speed is at or above 62 mph. Additionally, system performance may be limited when there is poor visibility due to insufficient illumination. In addition to reviewing Ford’s response to ODI’s IR, the agency conducted a review of crash and non-crash reports identified collectively through Ford’s IR response, incident reporting through Standing General Order 2021-01 (SGO), and NHTSA vehicle owner questionnaires. In total, 32 crashes and 2,004 non-crash reports on subject and peer Ford vehicles were identified across manufacturer and ODI data sources. A detailed analysis of each crash was conducted including the review of any available police reports, photographs, data recovered from in-vehicle event data recorders, connected vehicle data, and/or other information. In both fatal collisions referenced in the PE24012 opening resume, the subject Ford Mustang Mach-E vehicle was traveling over 70 mph on a controlled-access highway during nighttime lighting conditions with hands-free BlueCruise engaged when it collided with a stationary vehicle. Analysis of data imaged from the vehicles’ event data recorders demonstrates that in each incident, the driver did not apply the brakes or take evasive steering action, and no deceleration was initiated by either the BlueCruise system or PCA prior to impact. Through the agency’s crash analysis, four additional frontal collisions were identified where the subject Ford impacted a stopped or slow-moving lead vehicle or another stationary object located in the travel lane. Two of these four incidents involved BlueCruise-equipped Ford Mustang Mach-E vehicles (included in the failure report summary along with the fatal collisions discussed above), while the other two involved other Ford models equipped with the LCA system. Additionally, a trend was identified through analysis of the non-crash reports relating to allegations that ACC (the longitudinal component of both BlueCruise and LCA) failed to detect and/or respond to a stopped or slow-moving lead vehicle. In these reports, consumers often describe that the absence of deceleration initiated by ACC was unexpected and required harsh manual braking or intervention from the PCA to avoid a frontal collision with the lead vehicle. Based on NHTSA’s analysis, system limitations relating to the detection of stationary vehicles while traveling at highway speeds and in nighttime lighting conditions appear to be factors in collisions under investigation and several apparently similar near-miss, non-crash reports. This Preliminary Evaluation is being upgraded to an Engineering Analysis (EA25001) to further investigate these system limitations and to evaluate drivers’ ability to respond to scenarios that exceed system limitations. During the EA, the agency expects to, among other things, perform vehicle evaluations, review additional technical information, and perform additional analysis of related crashes and non-crash reports. The crashes included in the failure report summary can be found at NHTSA.gov under the following SGO report identification numbers: 502-7268, 502-7426, 502-6852, 502-8738.
RQ23004 · High Voltage Battery Contactor Failure
Opened Aug 17, 2023 · Closed Dec 6, 2023
Status: closed (inferred from source dates) · Electrical System:propulsion System:traction Battery:management System/energy Control Module (bms/becm):software; Engine And Engine Cooling:engine:engine Control Module (ecu/ecm):software
On August 17, 2023, the Office of Defects Investigations (ODI) opened RQ23-004 to investigate instances of loss of motor power due to overheating high voltage battery contactors in model year (MY) 2021-2022 Ford Mustang Mach-E vehicles (subject vehicles). This Recall Query (RQ) was opened after receiving 12 consumer complaints alleging a high voltage battery main contactor failure in subject vehicles that were included in Recall 22V-412 and remedied prior to the reported incidents. The remedy in 22V-412 was a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to prevent damage to the contactor, and a Battery Energy Control Module (BECM) software update to monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage. On October 13, 2023, Ford filed Recall 23V-687 of 34,762 2021-2022 Ford Mustang Mach-E vehicles produced from May 27, 2020 to May 24, 2022 with recalled Bussed Electrical Center parts NK48-10C666-AA, NK48-10C666-BA, or LK98-10C666-AB. Affected vehicles are equipped with the extended range battery. Ford stated that preexisting damage to the contactors caused by heat and accumulated wear may reduce the effectiveness of the software update remedy in 22V-412. The remedy of 23V-687 is to complete a replacement of the Bussed Electrical Center, or High Voltage Battery Junction Box. In addition, Ford stated that subject vehicles equipped with standard range batteries, in comparison to vehicles equipped with extended range batteries, are less at risk of experiencing this failure due to their smaller battery capacity and lower output electric drive motors. In view of the recall action taken by Ford, ODI is closing this investigation. ODI will continue to monitor reports of this failure in both extended range and standard range models. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Additional source detail variants (2)
Electrical System:propulsion System:traction Battery:management System/energy Control Module (bms/becm):software
On August 17, 2023, the Office of Defects Investigations (ODI) opened RQ23-004 to investigate instances of loss of motor power due to overheating high voltage battery contactors in model year (MY) 2021-2022 Ford Mustang Mach-E vehicles (subject vehicles). This Recall Query (RQ) was opened after receiving 12 consumer complaints alleging a high voltage battery main contactor failure in subject vehicles that were included in Recall 22V-412 and remedied prior to the reported incidents. The remedy in 22V-412 was a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to prevent damage to the contactor, and a Battery Energy Control Module (BECM) software update to monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage. On October 13, 2023, Ford filed Recall 23V-687 of 34,762 2021-2022 Ford Mustang Mach-E vehicles produced from May 27, 2020 to May 24, 2022 with recalled Bussed Electrical Center parts NK48-10C666-AA, NK48-10C666-BA, or LK98-10C666-AB. Affected vehicles are equipped with the extended range battery. Ford stated that preexisting damage to the contactors caused by heat and accumulated wear may reduce the effectiveness of the software update remedy in 22V-412. The remedy of 23V-687 is to complete a replacement of the Bussed Electrical Center, or High Voltage Battery Junction Box. In addition, Ford stated that subject vehicles equipped with standard range batteries, in comparison to vehicles equipped with extended range batteries, are less at risk of experiencing this failure due to their smaller battery capacity and lower output electric drive motors. In view of the recall action taken by Ford, ODI is closing this investigation. ODI will continue to monitor reports of this failure in both extended range and standard range models. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Engine And Engine Cooling:engine:engine Control Module (ecu/ecm):software
On August 17, 2023, the Office of Defects Investigations (ODI) opened RQ23-004 to investigate instances of loss of motor power due to overheating high voltage battery contactors in model year (MY) 2021-2022 Ford Mustang Mach-E vehicles (subject vehicles). This Recall Query (RQ) was opened after receiving 12 consumer complaints alleging a high voltage battery main contactor failure in subject vehicles that were included in Recall 22V-412 and remedied prior to the reported incidents. The remedy in 22V-412 was a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to prevent damage to the contactor, and a Battery Energy Control Module (BECM) software update to monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage. On October 13, 2023, Ford filed Recall 23V-687 of 34,762 2021-2022 Ford Mustang Mach-E vehicles produced from May 27, 2020 to May 24, 2022 with recalled Bussed Electrical Center parts NK48-10C666-AA, NK48-10C666-BA, or LK98-10C666-AB. Affected vehicles are equipped with the extended range battery. Ford stated that preexisting damage to the contactors caused by heat and accumulated wear may reduce the effectiveness of the software update remedy in 22V-412. The remedy of 23V-687 is to complete a replacement of the Bussed Electrical Center, or High Voltage Battery Junction Box. In addition, Ford stated that subject vehicles equipped with standard range batteries, in comparison to vehicles equipped with extended range batteries, are less at risk of experiencing this failure due to their smaller battery capacity and lower output electric drive motors. In view of the recall action taken by Ford, ODI is closing this investigation. ODI will continue to monitor reports of this failure in both extended range and standard range models. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
DP22005 · Pedestrian Alert Sounds
Opened Jan 27, 2023 · Closed Aug 7, 2023
Status: closed (inferred from source dates) · Electrical System:propulsion System
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.
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