NHTSA Complaint #11510276 — 2022 FORD MUSTANG MACH E

The HVBJB (high-voltage battery junction box) subassembly in ALL Ford Mach-e vehicles has known defects with insufficiently robust main contactors that are known to fail under normal charging and driving conditions as outlined in NHTSA Campaign Number 22V412000. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, and power brakes, as well as failure of other 12V systems due to inability to charge the 12V battery properly after contactors are damaged. Less catastrophic results can include failure to start, which can strand drivers and passengers in remote areas, bad weather conditions, and also cause loss of use for weeks due to delays in replacement parts and local dealerships needing equipment and training to effect removal/replacement of faulty unit with a new, more robust HVBJB.​ ​ My complaint is that Ford's recall under campaign 22V412000 is a software-only attempt to prevent future damage, and does not require the part(s) which are KNOWN to fail to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially stranding me in unsafe conditions unable to restart my vehicle.​ ​ I would like to see NHTSA strengthen the Ford recall to include both improved software AND removal/replacement of the HVBJB sub-assembly with the new, more robust parts without a known failure risk.​ Thank you very much for your time.