Ford Mustang Mach E overheating problems

Filed Apr 18, 2025 · Electrical · MA

The HVBJB failed on my 2024 Ford Mustang Mach-e. I first noticed a dashboard warning regarding a powertrain malfunction when I tried to start the car about a half-hour after we returned home from an approximately 170-mile drive five days ago. The warning said it was a powertrain malfunction and to get service soon. The car started an hour later and I was able to drive it to the Ford Service center where I bought the new car only last June. There they diagnosed the problem with this language: "HV JUNCTION BOX - FOUND P0AA1:68 AND P0AA1:00 TO BE HARD SET AND THE TO BE IN LIMP MODE. NEED TO REPLACE HV JUNCTION BOX ( 414-03A PPT P4 ) AND RETEST ALL MODULES. WILL NEED MORE TIME AFTER REPAIR TO TEST ALL SYSTEM. MEY NEED TO TAKE APART HV BATTERY AGIAN..." The service people told me that they need to keep the car for two weeks to replace the part and conduct follow-up tests. I know that the failed component has been the subject of two past recalls (2022, 2023) of the 2020-2022 model years for the Mach-e. The first recall resulted in Ford's attempt at a software fix, while the second required replacing the HVBJB in cars in which the software fix proved insufficient, presumably because the part had already been damaged before the fix and later failed under heat stress. Based on my experience this week it seems clear that neither recall resulted in Ford fixing the underlying problem with the part. Importantly, Ford says the part is subject to failure from overheating when drivers too often use high speed chargers (DC) or too often employ maximum acceleration. This admission contradicts Ford's own marketing of the car, which emphasizes its sportiness and fast acceleration, and its compatibility (with an adapter) with Tesla's large national network of superchargers. So the nature of the failing part is apparently wholly incompatible with what attracts many buyers to the car. Can the federal safety agency require Ford to make the necessary engineering fix to the part?

Filed Sep 23, 2024 · Electrical, Fuel system · FL

While driving the vehicle electrical console started flashing then lost power and stopped dead in the road. The battery was reading between 70% to 80% prior with a range of over 250 miles still available. Due to complete lack of any power the car could not be moved or placed into neutral for towing. It caused a traffic situation blocking 2 lanes of traffic for approximately 4 hours waiting for roadside assistance for jump start and towing. EV's cannot be towed like a regular car and not having access to the electronics made the car like a brick. Eventually I was able to attain assistance with a jump start that was able to provide enough power to drive onto the back of a tow truck and to the Ford dealership. Roadside assistance noted the 12-volt battery at the front of the vehicle was bulging and potentially overheated creating a potential explosion hazard and lack of electrical support to the main vehicle.

Filed Sep 15, 2024 · Electrical · NJ

The wireless charging pad for cell phones causes the phones to overheat and stop functioning properly. My fear is that an overheated phone could result in a fire. My understanding is that this issue exists not just for the charging pad on the Mach-E but other Ford models as well and across phone manufacturers.

Filed Jun 1, 2024 · Transmission · TX

This car has had multiple recalls and issues with the power train. It has affected my safety on multiple instances. The cars sensors went out die to the batter overheating and it was having trouble delivering power to the sensors and other parts of the vehicle. When the sensors went out, the car would malfunction and it would think we are about to crash so it would break on its own and do other weird technical things. When the battery overheats it also does not allow effect cooling of vehicle and I live in a state that is very hot. I have reported these issues to the dealer multiple times, but Ford has not put out a remedy for this issue yet.

Filed Apr 19, 2024 · Electrical, Fuel system · NV

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 federal safety agency 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 federal safety agency 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.

Filed Oct 3, 2023 · Electrical · TX

I want to draw attention to a significant concern: U.S. auto safety regulators announced in August of this year that they are currently investigating whether Ford Motor's 2022 recall of nearly 49,000 Ford Mustang Mach-E electric vehicles comprehensively addressed the associated safety concerns. The basis for the 2022 recall was that the high voltage battery main contactors could overheat, particularly from DC fast-charging and repeated wide-open pedal events. This overheating presents a very real danger as it could result in an immediate loss of power, markedly increasing the risk of a vehicular accident. Furthermore, after the recall, Ford issued a technical service bulletin, directing the replacement of the High Voltage Battery Junction Box on the recalled vehicles. However, the federal safety agency has since opened a recall query. This action was prompted by 12 consumer complaints related to Mach-E vehicles that had supposedly received the necessary recall fixes. It is worth noting that the High Voltage Battery Junction Box has been replaced on my Mach-E already, and I am still facing problems. This is my third encounter with this particular safety issue.

Filed Sep 20, 2023 · Electrical · CA

I am going to try to explain this as best as I can. Ford has faulty charging cables that they know about and have not recalled voluntarily. This I have an issue with because it is causing the battery on my car to overheat and put it at a potential risk of catastrophic thermal runaway incident. I have had two charging cables go bad on my car. I just got my car back today and I noticed the new cable has a new part number on it as well as different types of wiring marked on the outer portion of the top cable. This is the gauge of wiring that is being used to plug into the outlet of my home to the actual charging conversion. Look at the old and new cable pictures and notice the white markings on these cables the gauge or wiring is different. Now the part number of the one on the white car I am not sure at all which one was turned in as I no longer have it anymore but what I can tell you is on the white converter itself with part number LJ98-10f868-AL is the new part number cable which I just got and have no issues with. The other one part number LJ98-10f868-AK is the older part number cable that I have seen the amber light staying on that says that it's in an undercharging condition due to overheating. So with this said Ford is aware there is a defect in the charging cables of previous models prior to AL. I have had two other charging cables go bad before I just got this AL one how is this possible with no recall? These prior model charging cables are putting stress on the electrical system of the car. I can tell because with these old cables I hear the cooling fans coming on super loud which yeah the cooling fan is supposed to come on but im pretty sure the undercharging should not happen on the cable unless the battery is overheating. With this said you must open an investigation to look into these charging cables and what is changing the part numbers. It seems to me they are using different gauge wiring and type of wiring for the part that plugs into the wall.

Filed Sep 7, 2023 · Electrical · CA

So I have had 2 240v Ford charging cables go bad with a solid amber light on it and a pulsating blue light in the middle and no red light. This means according to the chart I saw online that the charging is reduced because it's overheating. So I drove it around on August 29th,2023 with a high temperature outside of 105 degrees F that day. The low I believe in Murrieta, CA that night was 70 degrees F. Since it's charging in the garage, you have to account for an extra 10-18 degrees F of heat since most garages are not air-conditioned. This coupled with the high voltage battery connector failure recall that is also currently being investigated leaves me to believe the battery itself may be overheating causing the high voltage battery connector to weld itself shut and 240v Ford charging cables to fry. With both of these issues currently happening I believe it puts us at a higher risk for a catastrophic thermal runaway event. My recommendation would be to check Ford's testing of the electrical battery system. Was it tested driven during 105 F weather then charged overnight multiple times on a 240V Ford charging cable that comes with the car? Was the fact that 10-18 Degrees F that a garage is much hotter then it is outside? I have had two charging cables fail with under 25k miles. This leads me to believe the battery is overheating and catastrophic thermal runaway is at a greater risk with all these issues. I do not want this thing to go into catastrophic thermal runaway while in my garage and hurt my family.

Filed Aug 21, 2023 · Electrical, Fuel system · CA

After receiving the remedy to the federal safety agency 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.

Filed Jun 15, 2023 · VA

I have 2023 Ford EV and my son also have 2022 Ford EV, too. We are living in the same house. All Ford mobile chargers with 240V do not work properly. It is supposed to charge at 7KWh but it drops 3Khw after few minutes charge. I switched to new Ford mobile charge, but it is faulty, too. Ford says its overheating issue but it happens during the winter season, too. I am concerning it might have faulty electric design and cause the fire at home. I checked the Ford Mach-e Forum, many of them have same problems.