Ford Mustang Mach-E Extended Range AWD

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 can result in total loss of drive power while driving or failure to start. Some owners report multiple replacements. The repair requires 14+ hours of labor because the battery pack must be dropped and opened. Covered under 8-year EV component warranty and the recall, but out-of-warranty replacement costs approximately 1,800-3,500 EUR. Verify recall completion with Ford before purchasing any 2021-2022 model.

Very common across all model years. The 12V battery only recharges after reaching 40% state of charge and then waits 48 hours before drawing energy from the high-voltage battery. Short drives do not allow sufficient charging. Software bugs, the Phone-as-a-Key system constantly polling, FordPass app checks, and aftermarket OBD-II dongles all accelerate drain. Ford issued recall 25S65 covering all 2021-2025 models (197,000+ vehicles) after reports of passengers being trapped inside when a dead 12V battery locked the electronic doors. The recall adds a software update to keep the DC-DC converter running for 12 minutes after shutdown. Replacement battery costs 150-300 EUR plus 50-100 EUR labor. Ford recommends preventive replacement every 3 years. An AGM upgrade battery can help.

The 15.5-inch SYNC 4A touchscreen is the car's sole interface for climate, navigation, and vehicle settings. Owners widely report 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 to reboot. Some owners need to do this weekly. Navigation failures also disable BlueCruise driver assistance. Most issues are software-related and can be 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 resolved.

AWD models have a front electric motor and associated half shafts that RWD versions lack. Ford recalled approximately 1,200 units (recall 22S55) for a right-rear half shaft manufactured with insufficient wall thickness that could break under load. AWD-specific issues also include front drive axle shaft joint failures (clicking noise when turning), front motor whine at 30-45 km/h when coasting, and intermittent 'AWD is temporarily disabled' warnings. A TSB exists for the motor whine with a PCM software update. Front half shaft replacement costs approximately 800-1,200 EUR. Complete front motor replacement, though rare, can reach 3,000-5,000 EUR. All covered under the 8-year EV component warranty.

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' 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 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. Beyond the recall, owners report stress cracks appearing without any impact. Ford sometimes disputes warranty coverage, claiming impact damage. The glass panel costs approximately 1,200-1,500 EUR, and labor is expensive because the windshield and rear hatch must also be removed, bringing total replacement to 1,500-3,000 EUR. Verify the roof adhesive recall is completed on early-build cars. Consider comprehensive glass coverage in your insurance policy.

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 has acknowledged the issue and revised suspension components for spring 2022+ production. Fixes include re-torquing control arms, replacing struts, and lubricating contact points. Cost varies from free under warranty to 200-1,000 EUR depending on the actual component causing the noise.