Ford Mustang Mach-E Extended Range RWD

Ford recalled approximately 35,000 Mach-E vehicles with extended range batteries built between May 2020 and May 2022 (recall 23S56). The high-voltage contactors inside the HVBJB overheat during DC fast charging and repeated hard acceleration, causing deformation that prevents proper contact or welds contactors shut. This triggers the 'Stop Safely Now' warning and total loss of drive power while driving, or failure to start. Repair requires dropping the battery pack and takes 14+ hours of labor. Covered under the 8-year EV component warranty and the recall, but out-of-warranty replacement costs 1,800-3,500 EUR. Post-June 2022 production uses updated hardware. Verify recall completion with Ford before purchasing any 2021-2022 model.

Very common across all model years. The 12V battery only recharges after reaching a minimum state of charge and then waits before drawing energy from the high-voltage battery. Short drives do not allow sufficient recharging. Software bugs, the Phone-as-a-Key system constantly polling, FordPass app checks, and aftermarket OBD-II dongles all accelerate drain. Ford issued TSB 25-2058 for 2021-2023 models addressing 12V drain through software updates, and recall 25S65 covering all 2021-2025 models (197,000+ vehicles) after reports of passengers being trapped inside when a dead 12V battery disabled the electronic doors. Replacement battery costs 150-300 EUR plus 50-100 EUR labor. Ford recommends preventive replacement every 3 years.

The 15.5-inch SYNC 4A touchscreen is the sole interface for climate, navigation, and vehicle settings. Owners widely report screen freezing, black screens, audio cutting out, and Apple CarPlay dropping connection. A temporary fix is holding volume down and seek right on the steering wheel for 10 seconds. Some owners need to reboot weekly. Navigation failures also disable BlueCruise driver assistance. Most issues are software-related and addressed by OTA updates or dealer reflashes. Persistent hardware failures require replacement of the APIM (Accessory Protocol Interface Module) at approximately 500-800 EUR out of warranty. The 2023+ software versions are more stable but the issue has not been fully eliminated.

More common on early 2021 models. The charge port door latch mechanism uses a plastic retainer that can break, preventing the door from opening or closing properly. The charge port itself may also fail, showing 'Plugged in not charging' errors or preventing cable release. Some owners report the port works at lower amperage but fails at higher charging rates, indicating a failing connector. Dealers typically replace the entire charge port assembly. Covered under the 8-year EV component warranty. Out of warranty: 400-1,200 EUR depending on whether just the door or the full port assembly needs replacement.

Ford recalled 13,544 Mach-E vehicles built between February 2020 and July 2021 for improperly bonded panoramic roof glass that could detach (recall 21S47). Beyond the recall, owners report stress cracks appearing without any impact, typically starting at the edges. Ford sometimes disputes warranty coverage, claiming impact damage. The glass panel costs approximately 1,200-1,500 EUR, and labor requires removing multiple components, bringing total replacement to 1,500-3,000 EUR. Verify the roof adhesive recall is completed on early-build cars.

Common on 2021-2022 models. Owners report creaking from rear wheel wells during low-speed body flex and front suspension creaking when reversing or turning at low speed. The issue worsens significantly in cold weather below -5 degrees Celsius. Some owners have had suspension components replaced multiple times without full resolution. Ford revised suspension components for spring 2022+ production. Fixes include re-torquing control arms, replacing struts, and lubricating contact points. Cost ranges from free under warranty to 200-800 EUR out of warranty.

A widespread cosmetic issue affecting multiple model years. The plastic door panels develop visible cracks around the e-latch door opening buttons. These start as hairline cracks and progress to clearly visible white stress marks. In severe cases, the cracks can allow water ingress into the door mechanism. Ford has replaced door panels under warranty in some cases, but some dealers consider it a cosmetic issue and decline coverage. Repair involves replacing the affected door panel trim piece at approximately 300-600 EUR per door out of warranty.