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Ford Motor Company has announced a safety recall, identified as NHTSA Campaign Number 25V441000, targeting specific 2022 Mustang Mach-E vehicles with extended range batteries. The recall addresses a critical issue where the high voltage battery main contactors may overheat, potentially leading to a loss of drive power and an increased risk of a crash. This action expands on a previous recall, 23V687, to ensure all affected vehicles are addressed.
Key Highlights
- Recall Scope: Impacts 239 Mustang Mach-E vehicles from 2022 with extended range batteries.
- Safety Risk: Overheated contactors may cause loss of motive power, heightening crash risk.
- Remedy: Free replacement of the Bussed Electrical Center (BEC) at Ford or Lincoln dealers.
- Consumer Advisory: Owners are advised to park outside and contact dealers for repairs.
- No Reported Incidents: Ford reports no accidents or injuries related to this issue.
Issue and Cause
The Bussed Electrical Center (BEC), also known as the High Voltage Battery Junction Box (HVBJB), in affected vehicles may experience overheating due to design and part-to-part variation. This issue can be exacerbated by repeated wide-open pedal events and DC fast-charging sessions, causing contactor damage. If contactors fail to close properly, vehicles may display a “Stop Safely Now” warning, lose power, and coast to a stop, though power brakes and steering remain functional. Alternatively, if contactors weld closed, a wrench light may appear on the next key cycle, preventing the vehicle from starting.
Remedy and Notifications
Ford dealers will replace the BEC at no cost to owners. Notification letters will be mailed starting July 14, 2025, with instructions to contact dealers. Owners can reach Ford Customer Service at 1-866-436-7332 and reference recall number 23S56. Ford advises parking vehicles outside until repairs are completed to mitigate risks.
Background and Investigation
Ford’s investigation, prompted by its obligations under a NHTSA consent order, revealed that the original recall population for 23V687 (approved October 6, 2023) omitted some vehicles due to an incorrect production cutoff date of May 24, 2022. The Cautitlan Assembly Plant ceased using affected BEC parts on May 27, 2022, prompting this recall expansion. As of June 25, 2025, Ford noted 22 warranty claims in North America but no crashes or injuries.
Component Details
The affected components, manufactured by TE Connectivity in Mexico, include the BEC for both Extended Range RWD and AWD models, identified by part number NK48-10C68B-AA. Ford’s proactive software detects contactor damage, alerting drivers via a wrench light or diagnostic trouble code (DTC).
Owner Actions
Owners should contact a Ford or Lincoln dealer to schedule a free BEC replacement and follow the “Do Not Drive, Park Outside” advisory until repairs are complete. For further details, visit Ford’s customer service page or NHTSA’s recall page. This recall underscores Ford’s commitment to addressing electrical system safety in electric vehicles.
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