2021 Ford Mustang Mach E Fuel system Problems

The HVBJB ($3500 + Tax) went on my car. It is out of battery system warranty by 25,000 miles (ended at 100,000 miles, I have 125,000 miles). I called Ford Corporate and they said they "have no current programs" to give me any good will discount on the repair. This is a big, known issue with Mustang Mach-e's There was a recall for this HVBJB part / system on many of the 2021 models, but somehow mine wasn't included in the recall. I cannot afford this repair, and I was hoping the NHTSA can get involved to get me some financial relief from Ford. There was also a safety issue as this morning when this all happened, the car forced me to stop at an intersection and would not move or restart. The police had to push me through the intersection. It's currently at Chapman Ford in Egg Harbour Townshop, NJ.

NHTSA ID

11755300

Incident

Aug 6, 2026

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. There were no warning lights before the failures occurred. During severe winter weather conditions in Pennsylvania, the lack of heat and defrost made it extremely difficult and unsafe to operate the vehicle. Because of reduced visibility and freezing interior temperatures, the vehicle could not be safely driven and, due to frigid temperatures, has remained parked. I am still making monthly payments on a vehicle that cannot be reliably or safely used.

NHTSA ID

11716499

Incident

Dec 3, 2025

Car stalled once while going to a military appt but started up 3 mins later. Car then made a noise then stalled out of nowhere on the highway at a slow speed in heavy traffic causing anxiety. vehicle then had me stranded waiting for a tow to find out it’s the HVJB .

NHTSA ID

11693497

Incident

Sep 27, 2025

It has several error messages including "Stop safely now". This seems to be the same issue as recall 23S56 (TSB 22-2178). The vehicle is not drivable as it will not start or go into gear. Seems to be known issue with the HVBJB.

NHTSA ID

11632397

Incident

Dec 23, 2024

It accelerated unexpectedly with no input while decelerating in one pedal drive mode. Cruise control was not in use at all during the drive.

NHTSA ID

11623040

Incident

Oct 29, 2024

Mach e standard edition shows multiple signs of a failing High Voltage Battery Junction Box (HVBJB). The vehicle was bought certified pre owned with only 12k miles on the vehicle. At 16k miles (2 months of ownership) the vehicle showed a high voltage battery warning and power train malfunction warning. Three warning lights were displayed on the dash which were: a yellow turtle, wrench, and car with exclamation. Vehicle was taken to service department where they ran updates and said the issue was a one pedal drive error and ran a standard osp for a power train update (not related to this power train issue). They made no mention of the battery and power train issue on the service record. 1-2 weeks later and about 1k miles, the same issue repeated. The vehicle was taken to a different dealership where they indicated the car had a over heating charge coupler and unbalanced battery "A". Both of these show a probable issue with the HVBJB. The dealership has been insistent that they can't do anything without a stored code. Prior OSP's updated the car to limit power when contactors in the HVBJB exceeded .5 ohms and would show all the warnings we have seen. The main 12 volt battery was replaced at 1k miles, which Ford did not realize the failure could have been from the HVBJB, as it receives charge from the primary batteries. The dealership and Ford engineers have requested that we drive the vehicle until the safety lights repeat, knowing that this puts us in danger of a larger malfunction that could result in complete loss of power while driving. They say that they cannot work on an issue unless a code is tripped. I suspect a code will not trip as the first two times nothing was stored and the OSP patch that NHSTS requested helps prevent the complete failure. The code will only be stored in a complete failure event, which could lead to an accident. There are current recalls for this HVBJB, however it is only for the higher end models. Out of space :) Thanks

NHTSA ID

11620777

Incident

Oct 3, 2024

Driving in a 40mph zone and car suddenly lost all power followed by a message stop safetly now and the 12v battery icon. While coasting car lost power steering and upon stopping went into park and would not go into neutral for 30+ minutes

NHTSA ID

11608571

Incident

Aug 13, 2024

Took vehicle to dealership for warranty repair as dealer confirmed parts available. Did not do repair due to Ford issuing a email to stop all repairs under this recall until further notice. Contacted Ford no reason why recall repairs stopped, no information when they would begin again. Ford recall notice blatant information without explanation. NHTSA site information is not accurate, parts are available but for undisclosed reasons they will not perform repair.

NHTSA ID

11587101

Incident

May 2, 2024

One pedal drive system failure. Had the 22B50 charge port recall done on the 18th of April 24. After leaving the dealer upon approach to a light one mile away, one pedal disengaged during de-acceleration for the light. Warning did come up near the same time. It felt like vehicle was accelerating, but just loss regen. It has since happened daily. sometimes multiple times. Restart the car and it works normal. The recall was to reprogram the BCCM according to the dealer.

NHTSA ID

11585171

Incident

Apr 18, 2024

This vehicle has 3 outstanding recalls: 21V711, 21V712, 23V687. The car was purchased new from Orchid Isle Ford in May 2021. They are the only electric vehicle Ford Dealer on Hawaii Island (they operate another non-electric vehicle dealership on the island). On [XXX] I had the annual maintenance performed. I requested that recalls 21V711 & 21V712 be done as well. the dealership declined and stated they would call me when they could do those recalls. They have never called. I started calling the dealership every 3 months beginning in Sept 2022. They have always refused to perform those recalls w/o explanation. In February 2024 I called to schedule the 36-month service and have all 3 recalls done. I was advised that the dealership could not do any of the recalls. I was called on Feb 23 by a person identifying themselves as the owner's sister (Mary) promising they'd make things right and asking for two weeks to arrange for the glass recalls to be done. I have had no contact since and have again been told by the service department that they can not and will not perform these recalls at any time regardless of where I bought the car. On [XXX], I emailed Ford Motor Company's CEO James Farley advising his office of the problem in getting three safety recalls performed on Hawaii Island. I have received no response from him, or any of the other emails sent to other officers of the Ford Motor Company nor have I even received an acknowledgment of receipt. At this point, I can only presume that Ford does not care if recalls are done. Recall 23V687 has the potential to strand me on rural roads where there is no cell service. The two glass recalls (21V711 & 21V712) can potentially cause death or serious injury in an accident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11585082

Incident

Mar 13, 2024

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. Ford needs to be proactively addressing this issue for all affected model years, not just certain configurations. Frankly it is wild that the NHTSA accepted a software update as an appropriate recall fix for a hardware component overheating and melting while driving. It didn’t work and should not be considered a fix.

NHTSA ID

11584119

Incident

Apr 10, 2024

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. When pressed further he then said that our vehicle was not part of the recall because the part was already replaced. When I explained that the part replace was the same defective part he told me to call the dealership or NHTSA because he would do nothing further. He went on to say that there was nothing further he would or could do, nor would it transfer me to anybody at Ford that could address our unique circumstances. Upon calling NHTSA they advised, (amongst other things), that we file a complaint via this portal.

NHTSA ID

11583689

Incident

Sep 30, 2023

Dashboard warnings about the high-voltage battery due to a fault. There is a known issue with the HVBJB (high-voltage battery junction box) plus a powertrain malfunction warning..

NHTSA ID

11548691

Incident

Oct 1, 2023

We came out to our parked car and got a message that said Stop Safely Now. The vehicle would not shift into gear. The dealership had confirmed that the high voltage junction box has failed. We did not get the Service Vehicle Soon warning prior to the failure, despite having had the recall software update applied. The first sign of failure was a loss of motive power. This is a safety issue because loss of motive power while driving can result in loss of control of the vehicle. The loss of heating and cooling combined with the loss of motive power is also a significant safety risk if the failure occurs in a remote location experiencing extreme temperatures. The part has yet to be replaced, but I’m sure Ford will be retaining it for inspection.

NHTSA ID

11547361

Incident

Aug 29, 2023

Shortly after entering the freeway on August 18, 2023, my vehicle experienced a powertrain malfunction and displayed a Service Vehicle Soon warning light along with a vehicle with an exclamation point light and a wrench light. Motive power was reduced. I received a Diagnostic Test Code of P0ADA, indicating that there was a hybrid powertrain fault. The dealer has confirmed the code and is ordering a replacement part.

NHTSA ID

11540062

Incident

Aug 18, 2023

I am filing this complaint regarding the potential failure of the High Voltage Battery Junction Box. There have been many failures reported on the forums some experiencing multiple failures. Ford provided a software update that supposedly predicts an impending failure reducing available propulsion power. I do not feel comfortable driving a vehicle with a ticking time bomb. Losing propulsion power while driving at highway speeds could result in a serious safety senerio. I would like to see Ford provide a real fix.

NHTSA ID

11540005

Incident

Dec 30, 2020

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with 'under-designed' main contacts that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only AFTER the 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 contacts 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 'beefier' components.​ ​ My complaint is that Ford's recall notice 22s41 is a software-only attempt to prevent future damage, and does not require removal of 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 re-start 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 'beefier' parts.​

NHTSA ID

11539965

Incident

Aug 20, 2023

After receiving the remedy to NHTSA campaign 22V-412 on Aug 5, 2022 via a Ford Power-Up over-the-air update, my high-voltage battery contactors still overheated and failed on Oct 25, 2022, requiring warrantied replacement by my Ford dealer on Oct 27, 2022.

NHTSA ID

11539925

Incident

Oct 25, 2022

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.

NHTSA ID

11539803

Incident

Aug 18, 2023

Unintended acceleration from a stop when pushing accelerator. Has happened 2 times in the last 2 days. I touched the throttle from a stop 2 time and it took off like I put the accelerator to full throttle (which I didn’t). Very dangerous situation in parking lots or around pedestrians. I have scheduled an apt with my local dealer.

NHTSA ID

11511215

Incident

Mar 9, 2023

Ford released an OTA update for the HVB issue Mach-E were having and leaving drivers stranded. I have seen that even with the update many people are still having the cars break down while driving and needing the High Voltage Battery Connector replaced. I am worried that this may happen to my car one day while driving and could cause an accident or death. Is there anyway to force Ford to fix every car that had this issue before we break down? The temporary fix of software is not good. I think FOrd should be forced to recall all Mach-E and replace the connector before there is an accident that leads to deaths on the road.

NHTSA ID

11505796

Incident

Feb 6, 2023

I had been driving without issue, no warnings from the car. I parked at a gas station to get a snack. When I got back in the car could not be started or driven. It has to be placed on a flatbed and towed to the dealer. The message on start was “Stop safely now”. My vehicle had Safety Recall 22S41, which obviously does NOT fix the issue.

NHTSA ID

11486307

Incident

Sep 5, 2022

HVBJB failure

NHTSA ID

11486295

Incident

Sep 18, 2022

Ford is unable to apply software fix to resolve NHTSA Recall Number22V412 because Accessory Protocol Interface Module (APIM) needs to be replaced first. The APIM is not in supply and there is no estimated availability date.

NHTSA ID

11485050

Incident

Jul 1, 2022

My vehicle has 13,000 miles on it and I have been driving it without any problems until August 12, 2022 when I turned the vehicle on and there was "service now" and a "Battery service" message. I was aware of this problem because it was posted online and Ford has sent me mail about this problem but I thought it could be fixed by an over the air update, which I performed already. So I contacted the nearest dealer to book an appointment to remedy this issue but the next available appointment was on August 31st so it was 2 weeks from then. I decided to give it a shot and drive it and I was able to drive approximately 40 miles before the car shut down as I was turning right on a stoplight on my way to work. The propulsion did not work along with a series of multiple error messages on all systems. I was able to bring the car to the side of the road, in front of a tire service company's parking lot. I tried to start and restart it but to no avail. I called the nearest Ford dealership and they accepted my vehicle so I called a towing service to tow my vehicle to them. I decided to step out of the vehicle and inform the establishment about the situation and that I called a towing service already. When I tried to get in, the doors did not work anymore so I was not able to get in. The towing service arrived and told me to put my car to neutral gear so she can pull it up the bed of the tow truck. I said I could not get in and she stated that she might damage the vehicle if she tried to pull it while it is on park. I had no choice but to agree because I cannot get in the vehicle to change the gear. She had me sign a waiver that states that I accept any possible damages that the vehicle might incur during the towing process. She was able to get the vehicle on the tow truck and deliver it to the dealership I mentioned and now they are trying to repair it. I was aware of this issue beforehand but Ford stated that this issue can be resolved with a simple software update.

NHTSA ID

11479421

Incident

Aug 12, 2022