Ford Motor Company is recalling select 2021-2022 Ford Mustang Mach-E crossovers due to an issue with the High Voltage Battery Junction Box (HVBJB). This action follows a previous recall for an issue regarding the same model’s high voltage battery main contactors, which prompted an investigation by the National Highway Traffic Safety Administration (NHTSA) back in August.
The defect: in affected vehicles, the high voltage battery main contactors may overheat, which can result in a contactor that remains open or a contactor that welds closed.
The hazards: Some vehicles that have received the 22S41 software remedy will receive a malfunction indicator lamp (MIL) when resistance is measured higher than the threshold. Those vehicles will experience a reduction in vehicle power with an average of 50 percent of its rated power to prevent further damage to the contactors. The vehicle will still be able to accelerate to highway speeds safely with this power derate.
In some cases, the 22S41 remedy has not proactively detected damage to the contactors on Extended Range and GT vehicles. This can allow the contactor to weld closed or prevent the contactor from properly closing while driving. If the contactors weld closed while driving, upon the next key cycle, a MIL will be illuminated, vehicle diagnostics will set a DTC, and vehicle will not start.
If the contactors are prevented from closing while driving, vehicle diagnostics will set a DTC, a MIL will be illuminated, the vehicle will display “Stop Safely Now,” and the vehicle will immediately lose motive power. The vehicle will coast to a stop and all 12V systems including power brakes and steering will remain functional.
Ford is not aware of any accidents or injuries related to this issue.
Components: High Voltage Battery Junction Box
Affected vehicles: select 2021 Ford Mustang Mach-E models produced between May 27th, 2020 through December 23rd, 2021, along with 2022 Mach-E crossovers built between August 16th, 2021, and May 24th, 2022, at the Cuautitlan Assembly plant.
Number of vehicles affected: 30,013
The fix: dealers will receive a bulletin when parts ordering information and repair instructions will be available to support this safety recall.
Owners should: wait for communications from Ford, which will begin after repair instructions and parts ordering information have been provided to dealers. The Ford reference number for this recall is 22S41.
- Ford Customer Service: 1-866-436-7332
- FoMoCo Recall Number: 22S41
- NHTSA Toll-Free: 1-888-327-4236
- NHTSA (TTY): 1-800-424-9153
- NHTSA Website: www.nhtsa.gov