The National Highway Traffic Safety Administration (NHTSA) is reopening investigations into Ford Mustang Mach-E EVs randomly losing power. The sudden power loss complaints are continuing, even for Mach-Es that got the fix as part of the previous recall for the same problem. That recall was in June 2022 and took in almost 60,000 Mach E EVs.

The original recall was because Mach-E batteries could overheat due to bad high-voltage battery main contacts. A software patch was either over-the-air or dealer installed that monitored the contacts for heat. Should heat rise to a certain level, the patch can reduce the output power to cool the contacts down.

How many Mach-E recalls would this make?

But besides the patch, Ford also put out a technical service bulletin recommending the replacement of the junction box. These junction boxes oversee battery, motor, and charging system functions. But even with the patch and junction box replacement, complaints continue to come into the NHTSA. 

Now, the administration is opening what it says is a “recall query to assess Ford’s response” for those 60,000 Mach-E Mustangs already taken to dealers receiving the fix. Or should we say the supposed fix? It has received 12 owner complaints so far for the same issue from already “fixed” EVs. Ford says it is “working with NHTSA to support their investigation,” according to Automotive News. 

Should this become another recall, it would be the fifth for the Mustang Mach-E since its introduction in 2021. Besides the previous recall we mentioned above, there were three other safety recalls. One was for broken rear-end half shafts last August. A recall for improperly attached seat belts was issued in December 2021. And another for windshields and sunroofs popping out of Mach-Es due to issues with the bonding material affixing the glass.

Hasn’t Ford already had a ton of recalls this year?

Excessive Ford recalls are continuing to plague its products. Over the past two years, Ford has led all other automakers in the number of recalls it issues yearly. Last year it set a record of 68 recalls, the most by far of any car manufacturer. Over 8.6 million Ford vehicles were recalled.

In 2021, that number was only slightly better at 53 recalls. So far in 2023, there was hope that the Dearborn automaker would see far fewer recalls. Unfortunately, that doesn’t seem to be the case. So far this year, 31 recalls have affected over four million vehicles. 

This past May, Ford began its “zero-defect launch process” at each of its truck assembly plants. The effort adds several quality assurance checks at various portions of the assembly line to catch any problems or omissions as each truck is built. Let’s hope this helps to staunch the proliferation of recalls at Ford.