23S56 – High Voltage Battery Main Contactor Failure – 2021-2022 Ford Mustang Mach-E

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October 13, 2023 NHTSA CAMPAIGN NUMBER: 23V687000

High Voltage Battery Contactor May Overheat

An overheated high voltage battery contactor can result in a loss of drive power, increasing the risk of a crash.

 

NHTSA Campaign Number: 23V687

Manufacturer Ford Motor Company

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 34,762

 

Summary

Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang Mach-E vehicles equipped with an extended range battery. The high voltage battery main contactors may overheat.

 

Remedy

Dealers will replace the high voltage battery junction box, free of charge. Owner notification letters are expected to be mailed October 30, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23S56. Vehicles included in this recall that were previously repaired under recall 22V-412 will need to have the new remedy completed.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


October 16, 2023

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice –
Safety Recall 23S56
Certain 2021-2022 Model Year Mustang Mach-E Vehicles
High Voltage Battery Junction Box (HVBJB) Replacement and Powertrain Control
Module (PCM), Battery Energy Control Module (BECM), and Secondary On-Board Diagnostic Control Module C (SOBDMC) Software Update

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Mustang Mach-E 2021 Cuautitlan May 27, 2020 through December 23, 2021
2022 August 16, 2021 through May 24, 2022

US population of affected vehicles: 30,013. Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In the affected vehicles, the high voltage battery main contactors may overheat, which can result in a contactor that remains open or a contactor that welds closed.

Some vehicles that have received the 22S41 software remedy will receive a malfunction indicator lamp (MIL) when resistance is measured higher than the threshold.  Those vehicles will experience a reduction in vehicle power with an average of 50% of its rated power to prevent further damage to the contactors. The vehicle will still be able to accelerate to highway speeds safely with this power derate.

In some cases, the 22S41 remedy has not proactively detected damage to the contactors on Extended Range and GT vehicles. This can allow the contactor to weld closed or prevent the contactor from properly closing while driving.

If the contactors weld closed while driving, upon the next key cycle, a MIL will be illuminated, vehicle diagnostics will set a DTC, and vehicle will not start.

If the contactors are prevented from closing while driving, vehicle diagnostics will set a DTC, a MIL will be illuminated, the vehicle will display “Stop Safely Now” and the vehicle will immediately lose motive power.  The vehicle will coast to a stop and all 12V systems including power brakes and steering will remain functional.

 

SERVICE ACTION

DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. A complete Dealer Bulletin will be provided to dealers when parts ordering information and repair instructions will be available to support this safety recall. For new vehicle storage guidelines, refer to EFC13033, Storage Guidelines for New Vehicles.

IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published. Opening an RO against an Awareness or Advance Notice will result in warranty rejections against a recall.

 

CUSTOMER NOTIFICATION

Owners of record will be notified via first-class mail after repair instructions and parts ordering information have been provided to dealers.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $26,315 per vehicle. Correct all vehicles in your new vehicle inventory prior to delivery.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 


23S56 – Certain 2021-22 model Ford Mustang Mach-E vehicles – High Voltage Battery Main Contactor Failure

Chronology of Defect: Submitted 13-Oct 2023

On June 3, 2022, Ford’s Field Review Committee (FRC) approved a Field Service Action (FSA) 22S41 to address potential high voltage battery main contactor over-heating concerns on certain 2021-2022 Mustang Mach-E vehicles. The service fix for 22S41 is for dealers to update Secondary On-Board Diagnostic Control Module (SOBDMC) and the Battery Energy Control Module (BECM) software. The updated SOBDMC software monitors contactor temperature and intelligently reduces battery power to prevent further damage to the contactor. The updated BECM software monitors contactor resistance to identify a damaged contactor and will issue a diagnostic trouble code (DTC) and reduce vehicle power to prevent further damage.

At the time of this FSA approval, Ford’s Critical Concern Review Group (CCRG) and Electrical Propulsion Engineering (EPE) teams judged the BECM and SOBDMC software updates to be an acceptable method of preventing the safety risk associated with a loss of motive power.  The software update addressed the risk of loss of motive power by monitoring contactor resistance.  Customers would receive a warning (described above) when resistance was measured higher than the threshold.  In addition to this warning, the software would reduce power to prevent further damage to the contactors and address the risk of loss of motive power. The customer would still be able to accelerate to highway speeds safely with this power derate. This approach was also reviewed with the National Highway Traffic Safety Administration (NHTSA) at this time.

August – October 2023:

On August 17, 2023, National Highway Traffic Safety Administration (NHTSA) informed Ford that they had opened a Recall Query to assess the remedy of FSA 22S41. Specifically, for vehicles that alleged a loss of motive power after the completion of 22S41. Ford opened an investigation in CCRG to manage the Recall Query response to NHTSA.

In reviewing updated field data as part of Ford’s ongoing monitor of recall effectiveness, CCRG and EPE reassessed their previous recommendations. Based on the new assessment, Extended Range and GT will receive a replacement Bussed Electrical Center (BEC) also referred to as the High Voltage Battery Junction Box (HVBJB).

The CCRG is not recommending any additional action on the Standard Range variants previously included in 22S41 because the Standard Range variation will see much less power at the contactors and has a much lower probability of latent contactor damage. Field data received after the completion of 22S41 shows that the remedy addressed the risk of loss of motive power for the Standard Range variants.

As of October 4, 2023, Ford is aware of 107 instances of high voltage contactor over-heating that resulted in a loss of motive power after completion of 22S41. 100 of these instances are on Extended Range or GT variants.

Ford is not aware of any accidents or injuries related to this concern.

 


22S41 – Secondary On-Board Diagnostic Control Module (SOBDMC) and Battery Energy Control Module (BECM) Software Update – 2021-2022 Ford Mustang Mach-E

 

22S41 – Secondary On-Board Diagnostic Control Module (SOBDMC) and Battery Energy Control Module (BECM) Software Update – 2021-2022 Ford Mustang Mach-E

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
FORD MUSTANG MACH E 2021-2022

 


4 Associated Documents

Defect Notice 573 Report

RCLRPT-23V687-1334.PDF 215.297KB

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Recall Acknowledgement

RCAK-23V687-2260.pdf 645.504KB

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Miscellaneous Document – Chronology of Defect

RMISC-23V687-5070.pdf 14.489KB

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Manufacturer Notices(to Dealers,etc) – Dealer Message Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S56 Certain 2021-2022 Model Year Mustang Mach-E Vehicles High Voltage Battery Junction Box (HVBJB) Replacement and Powertrain Control Module (PCM), Battery Energy Control Module (BECM), and Secondary On-Board Diagnostic Control Module C (SOBDMC) Software Update

RCMN-23V687-1588.pdf 46.435KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V687&docType=RCL

 


1 Associated Investigation

High Voltage Battery Contactor Failure
NHTSA ID: RQ23004
Dated opened: August 17, 2023

On June 10, 2022, Ford Motor Company (Ford) issued a safety recall (NHTSA Recall 22V-412) on 48,924 model year (MY) 2021-2022 Ford Mustang Mach-E vehicles produced from May 27, 2020, to May 24, 2022. This recall addressed high voltage battery main contactors that may overheat from direct current (“DC”) fast-charging and repeated wide-open pedal events. Overheating may lead to arcing or deformation of the electrical contact surfaces, which may result in a contactor that remains open or a contactor that welds closed. An overheated contactor that opens while driving may result in an immediate loss of motive power without re-engagement, increasing the risk of a crash.

The Office of Defects Investigation (ODI) has opened this Recall Query (RQ) after receiving 12 consumer complaints alleging a high voltage battery main contactor failure in MY 2021-2022 Ford Mach-E vehicles (subject vehicles) that were included in Recall 22V-412 and remedied prior to the reported incidents. The remedy in this recall was a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to prevent damage to the contactor, and a Battery Energy Control Module (BECM) software update to monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage.

Following the recall, Ford issued Technical Service Bulletin TSB 23-2020, to replace the High Voltage Battery Junction Box (HVBJB) on the subject vehicles. Consumers who experienced loss of motive power after receiving the recall remedy reported that their vehicle had the HVBJB replaced, as outlined in TSB 23-2020, to properly remedy the failure of the contactors. This RQ has been opened to assess the remedy of Recall 22V-412.

The ODI complaints cited above can be viewed at NHTSA.gov under the following ODI identification numbers: 11472202, 11475350, 11477025, 11479095, 11479421, 11485995, 11493140, 11510437, 11511316, 11517977, 11525550, 11526050.

 


 

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