2022 Ford Mustang Mach-E: Extended Range Battery Power Loss

On 2025-07-09 08:38:59

Ford Motor Company has decided that there is a safety issue affecting certain 2022 Mustang Mach-E vehicles equipped with the extended range battery. They are warning owners that the problem could lead to sudden power loss while driving. This recall highlights a critical issue with the high voltage battery main contactors, which may overheat under specific conditions.

If you own a 2022 Mustang Mach-E, here’s what you need to know about this recall, how it can affect your vehicle’s performance and safety, and what your options are if you’ve experienced repeated problems.

What’s the Problem With the Mustang Mach-E Extended Range Battery?

Ford is recalling certain 2022 Mustang Mach-E vehicles equipped with the extended range battery but without the GT powertrain because the high voltage battery main contactors may overheat.

How Does It Happen?

  • The overheating is linked to DC fast charging combined with repeated wide open pedal events (hard acceleration).
  • This can cause excessive heat, leading to arcing and deformation of the electrical contact surfaces inside the high voltage battery junction box.

This can cause excessive heat, leading to arcing and deformation of the electrical contact surfaces inside the high voltage battery junction box.

What Can Go Wrong?

  • The contactors might fail to close, preventing the car from starting or operating.
  • Even more concerning, the contactors could weld closed, meaning they stay stuck. While this won’t immediately affect driving, once you shut the car off, the next attempt to start it will fail, triggering a wrench light and preventing the vehicle from moving.

In more severe cases:

  • If the contactors fail to close properly while driving, the vehicle will trigger a “Stop Safely Now” warning, immediately lose motive power, and coast to a stop.
  • Thankfully, all 12V systems like power steering and brakes remain operational, reducing the risk of total loss of control.

How Did Ford Respond?

This issue isn’t entirely new. Back on October 6, 2023, Ford launched field action 23V-687 (23S56) to address overheating from fast charging and aggressive driving. However, due to a cutoff date error, some affected vehicles were left out.

Ford’s continued investigation — partly driven by obligations under its consent order with the National Highway Traffic Safety Administration (NHTSA) revealed that the problematic Bussed Electrical Center (BEC) components actually stayed in production until May 27, 2022, not May 24 as originally thought. So on June 20, 2025, Ford’s Field Review Committee approved expanding the recall to include more vehicles under NHTSA recall number 25V-441, amending the earlier recall.

How Widespread is the Problem?

As of June 25, 2025, Ford acknowledged 22 warranty claims in North America related to this high voltage battery junction box issue, between October 2022 and February 2025. While there have been no reports of accidents or injuries, the possibility of losing power while driving is a serious concern.

How Will Ford Fix This Mustang Mach-E Recall Issue?

Ford dealerships will replace the high voltage battery junction box.

  • Owner notification letters are expected to be mailed starting July 14, 2025.
  • If your car is affected, you’ll be instructed to bring it in for the repair.

Even though many vehicles were already built with software intended to detect and warn of this issue (via recall 22V412/22S41), damage may have already occurred due to heat and repeated stress. This reduces the software’s effectiveness in catching failures early, making the hardware replacement critical.

Could This Make Your Mustang Mach-E a Lemon?

Repeated electrical or battery system problems can severely impact the use, safety, and value of your vehicle. If your Mustang Mach-E continues to have issues after multiple attempts to fix it, or if it spends a significant amount of time in the shop, it may qualify as a lemon under state lemon laws.

Generally, to qualify for a lemon law claim:

  • Your car must have a substantial defect covered by warranty.
  • The manufacturer must fail to repair it after a reasonable number of attempts.
  • Or, your vehicle is out of service for repairs for a certain number of days (often 30 or more).

What Should Mustang Mach-E Owners Do Now?

✅ Check your VIN: Look up your vehicle on the NHTSA recalls website or Ford’s recall page to see if you’re included.
✅ Schedule repairs promptly: Don’t delay — replacing the junction box is essential for safety.
✅ Document everything: Keep records of all recall work, invoices, and any incidents (like unexpected shutdowns or warnings).
✅ Consider your legal rights: If problems persist, talk to a lemon law attorney in your state to explore your options for a buyback or compensation.

Bottom Line: Don’t Ignore This Ford Mustang Mach-E Recall

The 2022 Ford Mustang Mach-E extended range battery issue is more than an inconvenience — it could cause your EV to stop running while driving, putting you and others at risk.

If your Mustang Mach-E has been plagued by repeated battery or electrical problems, know that you may have protections under state and federal laws, including potential remedies under the lemon law.