Ford is recalling 48,924 Mustang Mach-E electric vehicles in the United States. A problem with the high voltage battery contactor could also result in a loss of engine power while driving, creating a risk of an accident. A software update should help, even if Ford's problem description leaves open why it should work.
Frequent fast-charging or full-throttle lead to the problem
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In the almost 50,000 vehicles potentially affected, repeated charging with direct current (rapid charging) and/or frequent retrieval of the full engine performance by pressing the accelerator pedal can lead to the contactors heating up too much as a result of the very high currents flowing in this situation . This can result in a malfunction that manifests itself in two different ways: Either the contactor no longer closes properly while driving and only transmits insufficient electrical power to the motor, which results in power losses. Or it is permanently closed because the contact surfaces have been welded together.
According to Ford, neither the design chosen nor the fact that the components have variances are designed for these high temperatures. The message is: The hardware is the problem.
Software update should fix the heat problem
However, a software update should solve it, which should also be available over-the-air from July 2022. However, this should only help if the temperatures are too high because the contactor is switched incorrectly or at the wrong time and the switching behavior is adjusted. It cannot be assumed that Ford is only reducing the maximum permissible current flow and thus maximum performance and charging capacity.
The fact that only some of the vehicles are affected, according to CNBC all models manufactured in the Mexican plant from May 27, 2020 to May 24, 2022, indicates that the software was not perfectly adapted to the hardware used in this plant during this period.
The highest thermal loads occur when the relay is switched under load and arcing occurs as a result. However, Ford itself does not establish this specific connection.
The fact that CNBC also reports that Ford has informed dealers that it will write to affected customers as soon as repair and replacement parts However, there is some information that raises doubts that ultimately only a software update for the Secondary On-Board Diagnostic Control Module and the Battery Energy Control Module could help.
The almost 50,000 owners affected should be able to find out about this with the official letter at the latest. Until then, they can continue to use their Mustang Mach-E as usual, says Ford.