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

SEOCONTENT-START

OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-687 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : OCT 13, 2023 NHTSA Recall No. : 23V-687 Manufacturer Recall No. : 23S56 Manufacturer Information : Manufacturer Name : Ford Motor Company Address : 330 Town Center Drive Suite 500 Dearborn MI 48126-2738 Company phone : 1-866-436-7332 Population : Number of potentially involved : 34,762 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Ford Mustang Mach-E Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC Descriptive Information : The recalled Bussed Electrical Center parts NK48-10C666-AA, NK48-10C666-BA, or LK98-10C666-AB were introduced into production on 05/27/2020 and were taken out of production on 05/24/2022. Affected vehicles are equipped with the extended range battery. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : MAY 27, 2020 – MAY 24, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Direct Current (“DC”) fast charging and repeated wide open pedal events can cause the high voltage battery main contactors to overheat. Overheating may lead to arcing and deformation of the electrical contact surfaces, which can result in a contactor that is prevented from closing or a contactor that welds closed. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : An overheated contactor that is prevented from properly closing while Part 573 Safety Recall Report 23V-687 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of the Safety Risk : driving can result in a loss of motive power, which can increase the risk of a crash. Description of the Cause : The high voltage battery Bussed Electrical Center (BEC) main contactor design and part-to-part variation is not robust to heat generated from multiple wideopen pedal and DC Fast-Charge events. Damage to the Extended Range and GT contactors caused by heat and accumulated wear during customer usage prior to the software update may reduce the effectiveness of the software deployed with 22S41. If the contactors are damaged, the contactors may be prevented from properly closing or weld closed when driving. Identification of Any Warning that can Occur : For those vehicles that previously received the 22S41 remedy, in most cases, the software will proactively detect damage to the contactors and display a warning to the customer. If the contactors weld closed while driving, there will be no immediate effect on vehicle operation. Upon the next key cycle, a wrench light will be illuminated, vehicle diagnostics will set a DTC and vehicle will not start. If the contactors are prevented from properly closing while driving, vehicle diagnostics will set a DTC, a wrench light 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. Involved Components : Component Name 1 : Bussed Electrical Center Component Description : BEC – Extended Range RWD Component Part Number : NK48-10C666-AA Component Name 2 : Bussed Electrical Center Component Description : BEC – Extended Range AWD Component Part Number : NK48-10C666-BA Component Name 3 : Bussed Electrical Center Component Description : BEC – GT Component Part Number : LK98-10C666-AB Part 573 Safety Recall Report 23V-687 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Supplier Identification : Component Manufacturer Name : TE Connectivity Address : Blvd. Industrial Norte #23 & Blvd. Solid Hermosillo Foreign States 83118 Country : Mexico Chronology : Chronology is provided as an attachment Description of Remedy : Description of Remedy Program : Owners will be directed to take their vehicle to a Ford or Lincoln dealer to complete a replacement of the Bussed Electrical Center (BEC) also referred to as the High Voltage Battery Junction Box (HVBJB) as per workshop manual. There will be no charge for this service. Ford provided the general reimbursement plan for the cost of remedies paid for by vehicle owners prior to notification of a safety recall in May 2023. The ending date for reimbursement eligibility is estimated to be March 31, 2024. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : The updated BEC (NK48-10C666-AC, NK48-10C666-BC, LK98-10C666-AD) design has flat contact surfaces and the groove on the movable contactor surface is removed. Identify How/When Recall Condition was Corrected in Production : The updated BEC hardware design was introduced into production on May 25, 2022. Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on October 16, 2023. Mailing of owner notification letters is expected to begin October 30, 2023 and is expected to be completed by November 10, 2023. Planned Dealer Notification Date : OCT 16, 2023 – OCT 16, 2023 Planned Owner Notification Date : OCT 30, 2023 – NOV 10, 2023 Part 573 Safety Recall Report 23V-687 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported

**************************************************************************************************************

Ó Copyright 2023 Ford Motor Company Stacy L. Balzer Ford Motor Company Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan 48121 Ford Customer Service Division October 16, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: 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 REF: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S41-S1 Dated: October 7, 2022 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. Ó Copyright 2023 Ford Motor Company 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. QUESTIONS & ASSISTANCE For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician System (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab. Sincerely, Stacy L. Balzer

**************************************************************************************************************

**************************************************************************************************************

**************************************************************************************************************

SEOCONTENT-END