2021 Ford Mustang Mach E Fuel System Problems

Owner reports

Selected complaints filed with NHTSA by 2021 Ford Mustang Mach E owners, lightly cleaned up (personal details are redacted by NHTSA).

While parking in a garage the vehicle unexpectedly accelerated and ran into a wall. Anyone in or around the car may have been seriously ignored. The issues has happened twice but can not be reproduced by me. There we no indicators that the event was about to take place There is a recall for this on the vehicle type but not for the date of my manufacturing.

Bricked Mach E Extended Range with 10K miles and recently completed the roof and windscreen recall the week prior. Went to brunch and then came out to a car that would not start. Warning of "Stop Safely Now" even though the vehicle was driven to the location and then sat for 2 hours and was currently parked and still gave us this message. Low voltage (12 Volt) came in slightly low at 12.6 VDC. Attempted two jumps from another vehicle and a higher amperage tow truck with no change in error code nor would the vehicle "start". We resulted in doing a tow to a dealership for potential repair. Dealership has had it now for going on the third week. They are citing the replacement of the battery bus where the Low Voltage 12 VDC interfaces with the brains and main battery system. This has been cited before in the Mustang Mach E blogs. …

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 a follow up to ODI 11510437 that was filed via the phone in 2/2023 related to now NHTSA Recall 23V687. The vehicle in question experienced exactly the issue described in the recall notice. Our incident was part of the NHTSA investigation. The vehicle had its high voltage battery junction box replaced in +/- March 2023, but the new box was the same design as the old box that is poorly engineered. Notices sent out in Fall of 2023 indicating that there was a recall were not sent to us for this vehicle. Similarly, the notice sent in April 2024 informing Mach E owners to schedule appointments at their dealer was not sent to us for this vehicle. Upon contacting Ford, they indicated that this vehicle is not part of this recall. After insisting on speaking to a supervisor, he claimed that it was now a part of the recall but refused to provide me any written acknowledgment of this. …

After recall-related software updates were performed on my 2021 Ford Mustang Mach-E, the vehicle began experiencing repeated electrical and climate control failures. The heating and defrost system stopped working, leaving the vehicle without heat and causing the windows to fog, which reduces visibility in cold weather and creates unsafe driving conditions. The vehicle has been taken to multiple authorized Ford dealerships for inspection and repair; however, the problem returned immediately after the repair. The issue was reproduced and confirmed by a second dealer. A required part is currently on back order until the end of Feburary, leaving the vehicle unrepaired for an extended period. In addition, the vehicle experienced 12-volt battery failure and slow charging after the last recall update. These issues were not present prior to the recall. …

On April 10, 2024, my vehicle experienced a warning message to service vehicle and a sudden loss of power while I was driving on the freeway. The issue was caused by a failure in my high voltage battery junction block. Something that Ford had already issued a software update vehicle to my vehicle for a recall. However clearly the software update was not an appropriate fix for the issue and should not be considered fulfillment of the recall. In fact, Ford has an open recall for the extended battery configuration of my vehicle to proactively replace this defective part. I am reporting this issue to the NHTSA because clearly the software 'fix' did not resolve the safety issue AND it's scary that standard range batteries are neglected from the overall recall that applied to the rest of the model. …

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. …

On Friday 8/18/23 I was driving down a major freeway and my Mach-E jolted violently. I then received a "Stop Safely Now" and "Service Vehicle Soon" message. The vehicle lost all power at this time. Being on a very busy freeway my safety was at risk and I was luckily able to coast over to the right shoulder. The car refused to "start" after pulling over however the 12v battery did work so I was able to use accessories. Once towed to the dealer I was able to confirm a P0AA2 TSB code that indicated that a conductor was stuck open on the high voltage junction box. This was supposed to be fixed by a previous recall software update that FORD uploaded to my car however that was not the case. I am now without a car for 2 weeks but more importantly I am concerned for the safety of other Mach-E drivers as I am reading that this can happen again even after a hardware fix.

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 I returned to my car it failed to start.

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/

Fuel System complaints in other Mustang Mach E years