2021 FORD MUSTANG MACH E Electrical System Problems

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. 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... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as 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 HVBJB having re-designed...

We saw the recall warning and attempted to fix the issue but dealer stated it's been fixed over the air update. However, on July 21, there was a high voltage battery failure notice.

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. 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... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as 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 HVBJB having re-designed...

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. 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... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as 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 HVBJB having re-designed...

When placed in drive the car takes off on its own without the acceleration pedal being touched. The passenger locks only work with key fob unlock button being pressed and the passenger side doesn't recognize the Fob for easy entry. The adaptive cruise control warning comes on constantly. The handas free parking never worked since i got the car in July 2021.

When unplugging the vehicle from my home charger a large spark came out of the vehicle receptacle for the charging cable. This started happening a few weeks ago and has happened twice.

While returning from vacation, driving home on the highway, our car suddenly stopped working. We had been traveling at approximately 65 mph on SR 1 in Delaware when I accelerated to pass another vehicle and the car suddenly jolted forward and the engine seized. I received a warning to pull to a safe location as soon as possible. Thankfully, we were able to pull the car over to the shoulder of the highway without incident. The cars electrical system gradually shut down, limiting our ability to place the vehicle in neutral for towing. Approximately 250 miles from home and forced to wait more than 2 hours in the 90 degree weather with no AC, we were forced to bring the car to the nearest ford dealership in new castle Delaware. Since the battery and power completely failed, the dealership had to jump the 12 volt battery several times to get...

My vehicle was built with under-specked high voltage battery joint assembly bracket. The failure of this connection has caused many incidents whereby the car cannot start, or suddenly stops while driving. The part is either not to original specification or was not designed correctly. In either case, providing a SW fix to simply limit the voltage does not actually prevent or correct the problem. As this fix has rolled out, there are numerous reports of the issue still happening. This is because the fix doesn't fix the original condition, it only serves to limit the scope going forward. But if the part has been in use for 2 years as mine is, then the damage has already occurred and the fix will not prevent my issue. The appropriate fix for the problem is a replacement HVBJB, which Ford is only installing AFTER the incident occurs. This is totally unacceptable and...

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. 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... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as 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 HVBJB having re-designed...

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. 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... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as 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 HVBJB having re-designed...

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open NHTSA Campaign Number 22V412000 (Ford recall notice 22s41). 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... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as 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 HVBJB having...

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22s41. 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... and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can 'strand' driver's and passengers in remote areas, bad weather conditions, as well as 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 HVBJB having re-designed...

While legally passing a car on a 2-lane highway, at over 50+ mph, the car lost motive power and began to shut down leaving me with no power facing on coming traffic. I had no choice but to force other cars to slow down behind me, causing another hazard, in order to get to the side of the road. I could have been killed in an oncoming car collision.

I got the high voltage warning and my car shut down while driving it. The local ford dealership looked over the issue and has all the information

Car broke down twice due to defective high voltage junction block.

Driving our BEV Mach E at a normal speed, we got an error code, "Pull to the side of the road safely / stop safely" on our instrument display. The car turned itself off, and we had to slowly coast to the side of the road, which caused a lot of potential harm with other drivers not expecting our sudden course change - We activated our hazards, though. After cycling the car on/off, we were able to finish our drive home (about 8 more miles) with no further error codes. But this completely disabled the car and was extremely dangerous. If this had happened on the freeway or at night, and/or the vehicle would not have been able to be restarted, this would have been EXTREMELY DANGEROUS and is UNACCEPTABLE. Ford must be responsible for this, and must take action. Ford must fix the high voltage junction box, before someone...

Car would not move- "Stop Safely Now" error. Had to get it towed.

Car did not start - was in local grocery parking lot- needed to be towed to dealership.

On May 20, 2022, for the second time in a month my 2021 California 1 Mach e has had a catastrophic failure. It is less than a year old with 21,000mi. First time (April 20, 2022) I pulled out onto road after fast charging. Tonight, I started driving out of parking space after shopping. Emergency bells go off, all kinds of alerts and the car dies. You cannot get the gear cluster to turn...at all. Car will not turn off either. If this happens on a highway, it could be life endangering. First time it happened I was in Charlotte and Ford Dealer (Capital Ford) said it was 12v battery issue. Said they fixed it. I took it in to Palmetto Ford in Charleston to have it investigated further and they said it was fixed. That was two weeks ago. Now it's happened again. In second incident on May 20,...

Travelling from WI to NC using Electrify America DC fast chargers along the way. While in NC, got Stop Safely Now alert on screen and had to immediately pull over and stop where there was no shoulder. Could not move vehicle in any way after this. Could not put it in N, could not put it in Emergency Tow Mode. Had to wait 8 hours for tow with proper equipment. Issue was caused by failure of HVBJB - High Voltage Battery Junction Box which needed to be replaced.

After charging at Electrify America using DC Fast Charger, car windows stopped working, then safety alerts started flashing "Charge State Error" and "Stop safely now!" alerts. Car would not go forward but would go in Neutral some tries. Flatbed was able to load car and haul to closest dealer. Tech said High Voltage Junction Box went bad and needed to be replaced. 3 weeks later, part is replaced but windows don't work. Dealer says it will be 2 more weeks before windows can be repaired.

Stop Safely Now, HVJBC and BECM failure, car wouldn't shift or move.

Vehicle reported an electrical issue and would not let me take the vehicle out of park. Had to be towed to a local Ford Service Center. Have heard of similar issues from other owners.

I was stranded in a parking lot in the evening when my car wouldn't start. The vehicle displayed a "STOP SAFELY NOW" message and I couldn't get the car to move on its own. This happened on April 13, 2022. My safety was at risk because I was in a parking lot at night and unable to engage my car. I had to call and wait for a tow truck. The Ford dealership, in consultation with Ford engineers, confirmed that it was due to a faulty High Voltage Battery Junction Box (HVBJB) and it had to be replaced. With the faulty HVBJB, the car was undrivable. The HVBJB was inspected by Ford personnel and determined to be faulty. It was replaced under warranty. There were no other messages or warnings before my car failed to start. No prior symptoms. I drove normally to a store, parked the car, and when...

The vehicle started saying a door was ajar without indicating which one. Sometimes we would get an intruder alert while the car was plugged in at work but nothing was open or unlocked. Occasionally the passenger door would open on its own after turning off the car. Now we get a door fault alert after starting the car. We have contacted a local dealer as well as our purchasing dealer but both indicate. Month before they can see the car due to lack of qualified techs. Today, 4/26/2022 the passenger door opened on its own while at highway speed. Only the driver was in the car. The driver had to reach over to rematch the door. A dealer appointment was set two weeks prior for 5/12/2022.

While driving around a curve, my car lost all power and went completely dark. I didn't have brakes, steering, lights or any other functions. My car was completely bricked. This happened before daylight and I didn't have emergency flashers to notify other drivers I was stopped on the side of the road. After waiting for 6 hours for a tow truck, I went and tried to find the problem myself. I found a loose connection. It was the main power feed supplying the fuse box. Once I tightened it up, I was able to start and drive the car. I've attached a picture of the connection I tightened.

Was driving 55+ mph on freeway, was told by the car to 'stop safely' Had no accelleration, no power steering, came to a stop at a stop sign, could not shift to neutral to move it.

The High Volt Battery (HVB) would have a fault in charging sporadically. When this happens, the vehicle can't start. All the alerts for safety features come on and says that it's in accessory mode only. It's no longer in my possession for inspection. It was approved for lemon law buy back and is now owned by Ford Motor Company. They've recognized that the 12v battery drains dead when this happens and they were attempting to replace the ECM module, Battery Control Harness, and the HVB junction box to remedy the issue. My safety was put at risk in terms of when this happened. It was between -25 to -40 when this was occurring and the heat doesn't come on in accessory mode. There was the possibility of frostbite within 5-10 minutes if I didn't seek warm shelter. The problem was reproduced by the dealership where purchased [they have all the...

Drove my fully charged Mustang Mach E(MME) from TN to my daughter's school and to a local dealership to have some aftermarket wheels/tires installed (20 miles in total). Upon parking the vehicle in their service lane, I turned the vehicle off and handed them the keys. They get in the vehicle and try to turn it on and tell me "the vehicle won't turn on". I get in the vehicle myself and sure enough, the main dash display, screen display, transmission lights, etc are not working at all. After 7+ hours of trying to diagnose, there is apparently already a TSB out there for 12v batteries failing and other issues regarding the LVB (low voltage battery). None of these were ever addressed or reported to me. My vehicle is only 1.5 months old with 2k miles on it. The car is broken and completely inoperable at this point. Ford sent...

On 4/1, while entering the FWY @ about 50 mph under moderate accel, big thump (felt like the trans fell out), drivers display cycled thru multiple errors with "stop safely now" repeatedly flashing. Throttle went dead, speed dropped to 35 and steadily decreased. Was able to slowly exit FWY @ next exit, rolled thru light @ bottom of ramp and pulled over to the side of a busy side street. Came to a stop & car would not move. Put in park, cycled on/off several times. Would not come out of park. Tow truck arrived. Found emergency tow function in the main display. Tow driver hooked up front, put rears on dolly & towed to dealer.

The 12V battery drains to the point the car will not boot or go in gear. It spits about 8 error messages at you but none that say low 12V battery. This has now happened 3 times in the last year. This has left me stranded in the cold hundreds of miles from home one of those times. They are now saying that a high voltage junction box and a battery energy control module is required. After waiting 4 months for parts we will see soon I am hoping. Noted in additional details the first time it happened is referenced. OBD 2 ============1============== P0AA2 Raw code: 0AA2 ECU: 7EC Status: Confirmed OBDII: Hybrid battery positive contactor - circuit stuck open ============2============== U0594 Raw code: C594 ECU: 7EC Status: Confirmed OBDII: Invalid data received from hybrid powertrain control module

Car was parked in my home garage and would not start, displaying "Stop safely now." Vehicle appears to have code P0AA1 Hybrid battery positive contactor - circuit stuck closed. Many other Mach-E vechicles are exhibiting this defective part in the high voltage battery system, which appears to be the Battery Electrical Control Module (BECM). Ford appears to be aware of this issue, and, unconfirmed, has stopped production of the Mach-E to canibalize parts to fix vehicles that fail. However, some are less lucky than me and had their car stop dead while driving on the highway, and Ford should not be waiting for vehicles to stop and strand people before fixing this serious defect. Please see here for more info on my situation: https://www.macheforum.com/site/threads/%F0%9F%98%ADmach-n-cheese-stop-safely-now-%F0%9F%98%AD.16174/

The vehicle displayed "Stop Safely Now" on the instrument panel and would not drive. Required a tow to the dealer, High Voltage Battery removal, replacement of the High Voltage Battery Junction Box, and vehicle reassembly.

As the vehicle was braking to a stop at a stoplight the rear motors began chattering. The vehicle stopped and gave multiple error messages including "Shift System Fault" and "Stop Vehicle Safely." It locked the parking brake and could not be moved. It was stuck in the middle of a busy intersection on a county highway. It could not be driven or pushed out of traffic until the error cleared. It was a hazard to the occupants and other drivers on the road. 911 was called to get support with traffic. There was no indication before this failure occurred. It will be going in for service in 2 days. This is the second occurrence of the failure on this vehicle, the previous one at 2011 miles.

The contact owns a 2021 Ford Mustang Mach-E. The contact stated while attempting to start the vehicle, the stability track, traction control, and pre-collision warning lights were illuminated. The vehicle was not taken to a local dealer to be diagnosed or repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 200.

The tailgate on our 2 Mustang Mach E’s have spontaneously opened on their own several times. One time narrowly missing one of our 2 year grandsons and another time impacting a closed garage door resulting in approximately $1,500 in damage (State Farm Insurance Claim). The issue was not able to be reproduced at the Ford Service Department but has been reported to have occurred by several additional Mach E owners on the Mach E Forum. Both cars are available for inspection.

This vehicle is sold with a single key FOB and an option to use Phone As A Key software. This feature has been a continual source of problems, as reported by almost every purchaser. It has been updated numerous times, including a dealer installed software update. This is a serious safety issue. To unlock the key, you can use the traditional keypad on the door handle. This works consistently. However, once inside the vehicle, it can be impossible to have the car recognize the phone in my hand. Many owners report having to have the phone in a certain position, out of pocket or at a certain location in the car. Rebooting the phone, starting and stopping Bluetooth, getting out of the car, locking it and starting over again have all been mentioned. These work in a very hit or miss approach. I truly believe this software feature is still...

AS I WAS DRIVING DOWN THE ROAD (IN MOTION / CITY STREET) AT 30 MILES PER HOUR IN MY BRAND NEW (4 WEEK OLD / 2200 MILES) ALL ELECTRIC FORD MACH E, THE DISPLAY FLASHED MULTIPLE WARNING LIGHTS THAT CAME TOO QUICKLY TO DECIPHER, AND THEN THE CAR WENT DEAD. I WAS ABLE TO PULL OFF THE ROAD AND COME TO A STOP. AT THIS POINT THE CAR WAS COMPLETELY DEAD. EVEN THE HAZARD LIGHTS WOULDN'T WORK WHICH MADE THE SITUATION DANGEROUS SINCE THE CARS BEHIND ME COULD NOT TELL THAT THERE WAS A PROBLEM.