NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
27 reportsClear category filter40,000 miles · Jul 16, 2026
Electrical SystemPower Train
The contact owns a 2022 Ford Mustang Mach-E. The contact stated that while driving at an undisclosed speed, the vehicle became inoperable and the vehicle stalled, and the gear shifter was inoperable. The contact exited the vehicle and was unable to re-enter the vehicle because the doors were locked and failed to unlock. The mess…
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The contact owns a 2022 Ford Mustang Mach-E. The contact stated that while driving at an undisclosed speed, the vehicle became inoperable and the vehicle stalled, and the gear shifter was inoperable. The contact exited the vehicle and was unable to re-enter the vehicle because the doors were locked and failed to unlock. The messages "Service Now" and "Battery Management" were displayed on the instrument panel. The pre-collision sensor warning light and several other unknown warning lights were illuminated. The failure had occurred on several occasions. The vehicle was towed to the residence, and the batteries were replaced. The contact researched the issue and became aware of an unknown recall; however, the VIN was not included. The vehicle was taken to a dealer, where it was determined that the battery management system needed to be reset. The vehicle was repaired, and the dealer advised the contact to drive the vehicle for 30-40 miles. However, after approximately 3 miles, the message "Stop Now" was displayed on the instrument panel, and the failure persisted. The manufacturer was not notified of the failure. The failure mileage was approximately 40,000.
NHTSA ODI #11750812
Mileage unknown · Jun 6, 2026
Electrical SystemPower Train
On 6/4, I completed a long road trip of over 650 miles. When I got back into my vehicle to move it to where it would be parked for the night, it displayed messages for a Powertrain Malfunction/Reduced Power and a High Voltage Battery Warning. I powered the car off and back on within about 5 minutes, and the messages were still b…
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On 6/4, I completed a long road trip of over 650 miles. When I got back into my vehicle to move it to where it would be parked for the night, it displayed messages for a Powertrain Malfunction/Reduced Power and a High Voltage Battery Warning. I powered the car off and back on within about 5 minutes, and the messages were still being displayed. I connected a code scanner to the car and the car had stored codes P0D0F and P0AA4. Both of these codes indicated a fault with the High Voltage Battery Junction Box, a known issue with the Mustang Mach E. I was able to drive the car to a dealer the next day without incident but am wary of trusting the vehicle to make the same trip back home.
NHTSA ODI #11742422
Mileage unknown · Feb 25, 2026
Electrical SystemPower TrainUnknown Or OtherCrash
Vehicle shutdown while driving causing total power loss and hitting a parked vehicle. No alerts or notifications were present at the time.
NHTSA ODI #11720560
Mileage unknown · Feb 17, 2026
Electrical SystemEnginePower Train
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.…
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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 ODI #11718385
Mileage unknown · Sep 16, 2025
Power Train
I have a 2022 Mustang Mach-E GT and have now experienced two (2) High Voltage Battery Junction Box (HVJB) failures. First failure was in July 2023 when the vehicle had approximately 12,000 miles. I received the stop safely now message. Vehicle codes displayed via the Ford app showed a High Voltage Battery Warning and Power tra…
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I have a 2022 Mustang Mach-E GT and have now experienced two (2) High Voltage Battery Junction Box (HVJB) failures. First failure was in July 2023 when the vehicle had approximately 12,000 miles. I received the stop safely now message. Vehicle codes displayed via the Ford app showed a High Voltage Battery Warning and Power train Malfunction / Reduced Power warnings. I have now received this same failure and warnings again. The car currently has 54,000 miles and I was just advised by my dealer that the HVJB has failed a second time. My concern is that the replacement voltage boxes are nothing more than a Band-aid for the problem and not a permanent solution. As I prepare to receive by 3rd HVJB, I feel this is nothing more than a temporary fix until I receive another Stop Safely Now message while operating my vehicle. Please look into the HVJB failure rate for these vehicles. I am in online two Mustang Mach-E owners groups and this issue is rampant among owners. I feel this issue requires outside attention as Ford has now had 4 years to solve this issue for early produced Mach Es. Yet the issue continues to exist. Thank you for your attention in the matter.
NHTSA ODI #11687734
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 · Mar 10, 2025
Electrical SystemEnginePower Train
- 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 Ju…
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- 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 ODI #11647515
Mileage unknown · Dec 26, 2024
Electrical SystemEnginePower Train
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.…
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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 ODI #11632408
Mileage unknown · Sep 20, 2024
Forward Collision AvoidancePower TrainService Brakes
At highway speeds, the power brakes failed. In order to slow the car down, the brakes pedal had to be modulated with extreme force, upwards of 100 pounds of pressure on the brake pedal. As this happened, the car raised 4 Active Alerts - Powertrain Malfunction / Reduced Power - Antilock Brake Fault - Hill Start Assist Warning …
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At highway speeds, the power brakes failed. In order to slow the car down, the brakes pedal had to be modulated with extreme force, upwards of 100 pounds of pressure on the brake pedal. As this happened, the car raised 4 Active Alerts - Powertrain Malfunction / Reduced Power - Antilock Brake Fault - Hill Start Assist Warning - Pre-Collision Assist Not Available. It took a lot of force and distance to bring the car safely to a stop. After 20 minutes we restarted the car and it began to operate normally. The car was brought to a nearby dealer immediately, however, the dealership is unable to diagnose nor replicate the problem. ***We were extremely lucky there were no cars immediately in front of us, and that we have an extreme amount of room to stop. Had we been driving in traffic, there would have been an extremely high likelihood of an accident with injury.
NHTSA ODI #11615671
Mileage unknown · Aug 15, 2024
Electrical SystemPower TrainVehicle Speed Control
My car lunges forward randomly. I have called ford and went to ford several times.
NHTSA ODI #11608801
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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