The investigation is underway regarding Ford's Mustang Mach-E recall aimed at preventing power failures.

The NHTSA is re-examining a recall involving the Mustang Mach-E from last year, following complaints that the software update and service bulletin provided by Ford didn't resolve an issue that could lead to sudden power loss in the vehicles.

The National Highway Traffic Safety Administration (NHTSA) is initiating an investigation into Ford's handling of a recall that impacted nearly 49,000 Mustang Mach-E vehicles last year, according to a report by Automotive News. The recall, issued in June 2022, addressed a malfunction related to the overheating of the electric SUV's high-voltage contactors. In the most severe cases, this malfunction could result in the electric vehicle experiencing a sudden loss of power while driving, thereby raising the potential for a collision.

These instances frequently coincided with scenarios involving high-speed battery charging or repeated rapid acceleration sessions.

In response to the recall, Ford introduced an over-the-air (OTA) software update aimed at mitigating the risk of sudden power loss and potential contact damage resulting from overheating contactors. The company also halted the delivery of new Mach-E vehicles to dealerships until the software update was applied. Furthermore, Ford issued a service bulletin for the replacement of the High Voltage Battery Junction Box in impacted vehicles.

Presently, the National Highway Traffic Safety Administration's (NHTSA) Office of Defects Investigation has received 12 consumer complaints regarding the effectiveness of Ford's proposed solution.

The Recall Query (RQ) by the Office of Defects Investigation (ODI) has been initiated based on 12 consumer complaints regarding high voltage battery main contactor failures in MY 2021-2022 Ford Mach-E vehicles (subject vehicles) that had previously undergone the remedy outlined in Recall 22V-412. This recall solution involved a Secondary On-Board Diagnostic Control Module (SOBDMC) software update, which monitored contactor temperature to limit battery power and prevent contactor damage. Additionally, a Battery Energy Control Module (BECM) software update was implemented to monitor contactor resistance, identifying overheated contactors and reducing vehicle power to prevent further harm.

A complaint from a customer dated August 19th notes that they had to replace the High Voltage Battery Junction Box twice due to the same electrical system problem. Another complaint in February indicated that the issue recurred even after receiving the software update.

The initial recall impacted 48,924 Mustang Mach-E vehicles from 2021 and 2022, manufactured between May 27th, 2020, and May 24th, 2022, at Ford's Cuautitlan plant in Mexico. In relation to the ongoing investigation, NHTSA states that approximately 64,727 vehicles are now included in the inquiry.