Ford has issued a new recall for some 2021-2022 Mustang Mach-Es after discovering that some of the electric SUVs did not receive a previously required software update, despite being marked as repaired. The recall affects 234 vehicles in the US that may still be at risk of sudden power loss due to an overheating battery contactor.
Transport Canada has not yet issued a similar recall.
This recall stems from a prior issue addressed in Ford’s Safety Recall 22S41 (NHTSA recall number 24V-412), which was issued in 2022. That recall aimed to correct a defect where high-voltage battery main contactors could overheat under heavy acceleration or DC fast charging conditions. If these contactors overheated, they could either weld shut or remain open, potentially leading to a sudden loss of power while driving.
However, Ford has now identified that some vehicles were mistakenly marked as having received the necessary software update when, in fact, they did not. A flaw in the dealer service tool responsible for applying the update resulted in older software versions being installed instead of the intended fix.
Ford became aware of the issue in November 2024 when a quality audit flagged discrepancies in the software versions applied to vehicles that had undergone recall repairs. Further investigation throughout late 2024 and early 2025 confirmed that 98.6% of repairs were completed correctly, but a small number of vehicles still required the correct update.
Owners of the affected 2021-2022 Mustang Mach-E vehicles will have to bring their vehicle to their local dealership for a free software update.
Additionally, to prevent future errors, Ford has implemented a verification step requiring technicians to validate the software part numbers before closing the recall case.
You can read the full NHTSA recall notice below.
