NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
135 reportsMileage unknown · Sep 26, 2023
Electrical System
Vehicle experienced the recalled HVBJB failure around November 21, 2022 at 13,000 miles. The failed device was replaced. Around July 12, 2023 at 23,000 miles, the replaced HVBJB device failed again and was once again replaced. It seems that the replacement device does not resolve the issue. Both times, the vehicle was travel…
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Vehicle experienced the recalled HVBJB failure around November 21, 2022 at 13,000 miles. The failed device was replaced. Around July 12, 2023 at 23,000 miles, the replaced HVBJB device failed again and was once again replaced. It seems that the replacement device does not resolve the issue. Both times, the vehicle was traveling on the highway and the vehicle performance was instantly restricted causing a dangerous situation where I had to immediately move over to the right lane without any acceleration power to navigate around large trucks.
NHTSA ODI #11546519
Mileage unknown · Sep 20, 2023
Electrical System
I am going to try to explain this as best as I can. Ford has faulty charging cables that they know about and have not recalled voluntarily. This I have an issue with because it is causing the battery on my car to overheat and put it at a potential risk of catastrophic thermal runaway incident. I have had two charging cables go b…
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I am going to try to explain this as best as I can. Ford has faulty charging cables that they know about and have not recalled voluntarily. This I have an issue with because it is causing the battery on my car to overheat and put it at a potential risk of catastrophic thermal runaway incident. I have had two charging cables go bad on my car. I just got my car back today and I noticed the new cable has a new part number on it as well as different types of wiring marked on the outer portion of the top cable. This is the gauge of wiring that is being used to plug into the outlet of my home to the actual charging conversion. Look at the old and new cable pictures and notice the white markings on these cables the gauge or wiring is different. Now the part number of the one on the white car I am not sure at all which one was turned in as I no longer have it anymore but what I can tell you is on the white converter itself with part number LJ98-10f868-AL is the new part number cable which I just got and have no issues with. The other one part number LJ98-10f868-AK is the older part number cable that I have seen the amber light staying on that says that it's in an undercharging condition due to overheating. So with this said Ford is aware there is a defect in the charging cables of previous models prior to AL. I have had two other charging cables go bad before I just got this AL one how is this possible with no recall? These prior model charging cables are putting stress on the electrical system of the car. I can tell because with these old cables I hear the cooling fans coming on super loud which yeah the cooling fan is supposed to come on but im pretty sure the undercharging should not happen on the cable unless the battery is overheating. With this said you must open an investigation to look into these charging cables and what is changing the part numbers. It seems to me they are using different gauge wiring and type of wiring for the part that plugs into the wall.
NHTSA ODI #11545715
Mileage unknown · Sep 18, 2023
Forward Collision AvoidanceLane DepartureVehicle Speed Control
While driving on I-40 East between Raleigh, NC and Benson, NC I was trying to use the Blue Cruise self driving feature on my Mache. The system is frightening to me because it tends to default towards the marker between lanes and requires more attention than so called hands free driving is supposed to need. However, in this sit…
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While driving on I-40 East between Raleigh, NC and Benson, NC I was trying to use the Blue Cruise self driving feature on my Mache. The system is frightening to me because it tends to default towards the marker between lanes and requires more attention than so called hands free driving is supposed to need. However, in this situation, there was a stretch of the highway where the lane markers were half white and then half black stripes. When I hit that stretch the car veered over the lane markers into the passing lane and if I hadn't resumed control, would have taken me completely into the other lane. The dash indicated that the system was in control of the car for the entire time. It had not disengaged at any point.
NHTSA ODI #11545115
Mileage unknown · Sep 10, 2023
Electrical SystemUnknown Or Other
Suffered a “ stop safely now” error message. The battery warning light came on. Vehicle was parked at the time and suffered this error which wouldn’t let me start or shift into gear. I already had the HVJB replaced last year, September 2022.
NHTSA ODI #11543741
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
Mileage unknown · Sep 7, 2023
Electrical System
So I have had 2 240v Ford charging cables go bad with a solid amber light on it and a pulsating blue light in the middle and no red light. This means according to the chart I saw online that the charging is reduced because it's overheating. So I drove it around on August 29th,2023 with a high temperature outside of 105 degrees F…
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So I have had 2 240v Ford charging cables go bad with a solid amber light on it and a pulsating blue light in the middle and no red light. This means according to the chart I saw online that the charging is reduced because it's overheating. So I drove it around on August 29th,2023 with a high temperature outside of 105 degrees F that day. The low I believe in Murrieta, CA that night was 70 degrees F. Since it's charging in the garage, you have to account for an extra 10-18 degrees F of heat since most garages are not air-conditioned. This coupled with the high voltage battery connector failure recall that is also currently being investigated leaves me to believe the battery itself may be overheating causing the high voltage battery connector to weld itself shut and 240v Ford charging cables to fry. With both of these issues currently happening I believe it puts us at a higher risk for a catastrophic thermal runaway event. My recommendation would be to check Ford's testing of the electrical battery system. Was it tested driven during 105 F weather then charged overnight multiple times on a 240V Ford charging cable that comes with the car? Was the fact that 10-18 Degrees F that a garage is much hotter then it is outside? I have had two charging cables fail with under 25k miles. This leads me to believe the battery is overheating and catastrophic thermal runaway is at a greater risk with all these issues. I do not want this thing to go into catastrophic thermal runaway while in my garage and hurt my family.
NHTSA ODI #11543245
Mileage unknown · Sep 5, 2023
Electrical System
HVBJB failed on 2/1/23. We received the stop safely now alert and the vehicle would not start. Luckily not while driving, but leaving myself and daughter stranded at night. This is a known issue and there is a recall software patch available through Ford for the issue. It had been completed prior to this event. The software upda…
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HVBJB failed on 2/1/23. We received the stop safely now alert and the vehicle would not start. Luckily not while driving, but leaving myself and daughter stranded at night. This is a known issue and there is a recall software patch available through Ford for the issue. It had been completed prior to this event. The software update Ford offers isn’t sufficient to solve the problem.
NHTSA ODI #11542556
Mileage unknown · Sep 1, 2023
Lane DepartureSteering
While driving on the freeway at about 65 mph through a gradual left bend in the road, with fully active SuperCruise (lane keeping, active cruise control) and fully hands off, the vehicle suddenly veered into the adjacent right lane. The vehicle moved into the adjacent lane at a high rate, and could have resulted in a heavy side …
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While driving on the freeway at about 65 mph through a gradual left bend in the road, with fully active SuperCruise (lane keeping, active cruise control) and fully hands off, the vehicle suddenly veered into the adjacent right lane. The vehicle moved into the adjacent lane at a high rate, and could have resulted in a heavy side impact to a vehicle driving in that lane (and potentially rippling into the lane to the right of that as well). Throughout the deviation, SuperCruise remained active without warning lamps or any inducement of driver takeover. I caught the malfunction and manually overpowered the steering to bring the vehicle back into the original driving lane. The vehicle has no active open recalls, and is operating with the latest firmware updates installed. The vehicle has not been inspected by dealer, manufacturer, or any other group for any relating issues.
NHTSA ODI #11542066
Mileage unknown · Aug 24, 2023
Electrical SystemEquipment
Upon startup and without warning, the sound system emitted a very startling ear-piercing noise followed by very loud static which did not stop when radio was turned off. It finally stopped when I turned the car off but static started up again each time it was turned on. An hour later when the car was turned on it did not occur. …
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Upon startup and without warning, the sound system emitted a very startling ear-piercing noise followed by very loud static which did not stop when radio was turned off. It finally stopped when I turned the car off but static started up again each time it was turned on. An hour later when the car was turned on it did not occur. It was so loud that the car was undrivable not to mention how startling it was at the onset. I actually jumped out of the car when it happened. I’ve scheduled a service visit for next week.
NHTSA ODI #11540639
Mileage unknown · Aug 21, 2023
Fuel/propulsion SystemPower Train
Powertrain malfunction warning while driving to work on 55MPH road. This has occurred twice since buying the car new. November 14, 2022 with 9k miles was when the first warning/malfunction occurred. HVBJB was replaced. This last/second powertrain malfunction and High-Voltage battery warning occurred on May 26, 2023 with 15k …
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Powertrain malfunction warning while driving to work on 55MPH road. This has occurred twice since buying the car new. November 14, 2022 with 9k miles was when the first warning/malfunction occurred. HVBJB was replaced. This last/second powertrain malfunction and High-Voltage battery warning occurred on May 26, 2023 with 15k miles. HVBJB replaced again. This warning resulted in reduction of power, but not full loss of power. Unfortunately, the last time this occurred was when I was attempting to pass on a two lane road. The power reduction when this warning occurred prevented me from safely passing and getting back in to my lane. Image of warnings on my Ford app are attached for details and dates. Northfield Ford (Northfield, MN) replaced the HVBJB on both occurrences. I have never used a DC Fast Charger. Most used charger is 110v.
NHTSA ODI #11539849
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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