Ford Recalls All Mustang Mach-E Models For Battery Contactor Issue

June 16, 2022 by Kevin Clemens

Ford has recalled nearly 49,000 of its 2021-22 Mustang Mach-E electric vehicles that might not start or could lose power while driving. 

Ford will recall 48,924 Mustang Mach-E electric vehicles, addressing a problem with the battery contactor that could cause the EV to lose power when driving or not start. The contactor acts like a relay to connect the battery pack to the motor drive system. The problem, which was discovered by Ford, is caused by overheating of the battery pack main contactors. The EVs covered in the recall were built between May 27, 2020, and May 24, 2022.


Ford Mustang Mach-E

Image used courtesy of Ford


According to a statement by Ford on the National Highway Traffic Safety Administration (NHTSA), “Direct Current (“DC”) fast charging and repeated wide-open pedal events can cause the high-voltage battery main contactors to overheat. Overheating may lead to arcing and deformation of the electrical contact surfaces, which can result in a contactor that remains open or a contactor that welds closed.”


The High-Voltage Battery Main Contactor

NHTSA further describes the problem: "The design and part-to-part variation of the high-voltage battery main contactor is not robust to the heat generated during DC fast charging and multiple wide-open pedal events. If the contactor opens while driving, a powertrain malfunction warning light will be illuminated, and the vehicle will display ‘Stop Safely Now’ in the cluster when the vehicle experiences an immediate loss of motive power. Should the contactors weld closed while driving, a powertrain malfunction warning light will be illuminated on the next drive cycle, along with a no-start condition.”

Ford says a software update through an Over-The-Air (OTA) update or by visiting a dealer will be available in July. Under this safety recall, the company has not issued instructions to stop driving vehicles.


Feature image used courtesy of Ford