The 2022 Mach-E is Ford's first serious EV attempt on a high-volume platform, and while it's generally reliable for early electric tech, we're seeing specific high-voltage system quirks, HVJB failures, and some teething issues with the infotainment/12V architecture that strand vehicles unexpectedly.
High Voltage Battery Junction Box (HVJB) Failure
Occasional · high severity
Symptoms: Complete loss of power while driving, Vehicle won't start or go into ready mode, Wrench light with no codes or generic HV system faults, Clicking from under vehicle near battery pack
Fix: HVJB is mounted under the vehicle and houses contactors, fuses, and control logic for the high-voltage system. Failures often traced to moisture intrusion or internal contactor welding. Replacement requires pack isolation, underbody access, about 4-6 hours labor. Ford has issued TSBs and extended warranty coverage on some VINs through 22S56.
Estimated cost: $2,500-4,000
12-Volt Battery Drain / DC-DC Converter Issues
Common · medium severity
Symptoms: Dead 12V battery after sitting 2-5 days, Vehicle won't wake up or unlock, Repeated battery replacements don't fix the problem, SYNC screen frozen or black on startup
Fix: The DC-DC converter charges the 12V system from the HV pack, and early software calibrations had parasitic draw issues or converter faults. Ford released multiple OTA updates (Power-Up 3.6.0+) addressing this. If software doesn't fix it, DC-DC replacement is 3-4 hours labor. Some cases also involve gateway module reflash.
Estimated cost: $800-1,500
Rear Drive Unit Bearing Noise / Leak
Occasional · medium severity
Typical onset: 30,000-60,000 mi
Symptoms: Whining or grinding from rear on AWD models, increases with speed, Gear oil leak visible at rear motor seals, Vibration during acceleration
Fix: Ford issued recall 22S45 for rear drive unit bearing failure risk. Affected units get full drive motor replacement (R&R plus new unit). Job takes 6-8 hours including coolant system bleeding and alignment checks. Most covered under warranty or recall, but out-of-pocket it's steep.
Estimated cost: $4,500-7,000
Infotainment Screen Freeze / Black Screen of Death
Common · low severity
Symptoms: SYNC 4A screen unresponsive or black, Backup camera won't display, Climate controls inaccessible, System reboots randomly while driving
Fix: Usually software-related; hard reset (hold volume down + skip forward for 10+ seconds) or OTA update resolves most cases. Persistent failures can require APIM (module) replacement, 2-3 hours labor with programming. Ford has released multiple SYNC updates addressing stability.
Estimated cost: $150-300
Charge Port Door Latch / Motor Failure
Occasional · low severity
Typical onset: 40,000-80,000 mi
Symptoms: Charge door won't open electrically, Door stuck open or closed, Repeated open/close cycling on its own, Error message: 'Charge port door fault'
Fix: Electric latch motor or microswitch in the charge port door assembly fails, sometimes from ice/water exposure. Replacement involves rear quarter trim removal, 1.5-2 hours labor. Part availability has been spotty, so lead times can stretch.
Estimated cost: $400-700
Front Subframe Bolts Loosening (Recall 23S04)
Rare · high severity
Symptoms: Clunking from front suspension over bumps, Steering feel changes or looseness, Visible gap at subframe mounting points
Fix: Ford recalled certain 2021-2022 Mach-Es for improperly torqued front subframe bolts that can loosen and separate. Inspection and re-torque per service bulletin, about 1 hour labor. Critical safety issue if unaddressed—can lead to loss of steering control.
Estimated cost: $0
Heat Pump Failure / Insufficient Cabin Heat
Occasional · medium severity
Symptoms: Weak or no heat in cold weather below 20°F, Range drops dramatically in winter, Compressor noise changes or stops, Defrost barely functions
Fix: Heat pump system (optional on Premium/Select, standard on GT) can fail due to refrigerant leaks, compressor clutch issues, or control valve faults. Diagnosis requires AC machine and thermal imaging, repair is 4-6 hours including refrigerant recovery/recharge. Some cases covered under emissions warranty (8yr/80k mi).
Estimated cost: $1,800-3,200
Owner tips
Keep the 12V battery on a trickle charger if the vehicle sits more than a week—early DC-DC calibrations were rough on it
Subscribe to Ford Pass and enable auto-updates; many problems are resolved via OTA without a dealer visit
Check for open recalls by VIN—Ford has issued several safety-critical ones on early Mach-Es
If you live in a cold climate, budget for winter range loss of 30-40% and verify heat pump function before purchase
Extended warranty on HV components expires at 8yr/100k mi—after that, drive unit or HVJB failures get expensive fast
Buy a 2022 if it has a clean recall history and recent OTA updates, but budget for potential 12V headaches and verify all high-voltage systems function—early adopter tax is real, though Ford has been decent about covering the big stuff under warranty.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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ELECTRICAL SYSTEM:BODY CONTROL MODULE/BCM · 25V689000
2025-10-10
Ford Motor Company (Ford) is recalling certain 2021-2023 Mustang vehicles repaired incorrectly under recall number 23V727. The brake fluid level sensor may not activate the visual warning indicator when the brake fluid is low. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 135, "Light Vehicle Brake Systems."
Consequence: Without a low brake fluid warning light, the vehicle may be driven with low brake fluid, reducing braking performance and increasing the risk of a crash.
Remedy: Dealers will update the body control module software, free of charge. Owner notification letters were mailed December 11, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25C55. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning November 17, 2025.
Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving.
Consequence: An engine stall increases the risk of a crash.
Remedy: Dealers will replace the low pressure fuel pump on super duty vehicles and update the powertrain control module (PCM) software on all other affected vehicles, free of charge. Interim notification letters notifying owners of the safety risk were mailed July 16, 2025. Second letters will be sent once the remedy is available, anticipated 2nd Quarter 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S75.
BACK OVER PREVENTION:SOFTWARE · 25V442000
2025-06-27
Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
Consequence: A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations can increase the risk of a crash.
Remedy: Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.
STEERING:ELECTRIC POWER ASSIST SYSTEM · 25V096000
2025-02-14
Ford Motor Company (Ford) is recalling certain 2022-2023 Ford Mustang vehicles previously repaired incorrectly under recall number 24V-493. The secondary steering torque sensor may not be calibrated properly, which can cause the steering wheel to turn side to side against the driver's intentions.
Consequence: A steering wheel that turns unintentionally can cause a loss of vehicle control and increase the risk of a crash.
Remedy: Dealers will update the power steering control module (PSCM) software, free of charge. Owner notification letters were mailed March 25, 2025. Owners may contact Ford customer service at 866-436-7332. Ford's number for this recall is 25S11.
STEERING:ELECTRIC POWER ASSIST SYSTEM · 24V493000
2024-06-28
Ford Motor Company (Ford) is recalling certain 2022-2023 Ford Mustang vehicles. The secondary steering torque sensor may not be calibrated properly, which can cause the steering wheel to turn side to side against the driver's intentions.
Consequence: A steering wheel that turns unintentionally can cause a loss of vehicle control and increase the risk of a crash.
Remedy: Dealers will update the power steering control module (PSCM) software, free of charge. Owner notification letters were mailed on October 11, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S44.
ELECTRICAL SYSTEM:BODY CONTROL MODULE/BCM · 23V727000
2023-10-27
Ford Motor Company (Ford) is recalling certain 2020-2023 Mustang vehicles. The brake fluid level sensor may not activate the visual warning indicator when the brake fluid is low. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 135, "Light Vehicle Brake Systems."
Consequence: Without a low brake fluid warning light, the vehicle may be driven with low brake fluid, reducing braking performance and increasing the risk of a crash.
Remedy: Dealers will update the body control module software, free of charge. Owner notification letters were mailed December 21, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23C35.
POWER TRAIN:AUTOMATIC TRANSMISSION · 23V070000
2023-02-10
Ford Motor Company (Ford) is recalling certain 2022-2023 F-150, Mustang, Explorer, Bronco, and 2023 Lincoln Aviator vehicles equipped with automatic transmissions. The transmission may contain a loose bolt which could prevent the transmission from engaging the park gear, although the gear shifter position may indicate that the vehicle has been shifted to "PARK."
Consequence: The inability to secure the vehicle in the park position can result in a rollaway, increasing the risk of a crash or injury.
Remedy: Dealers will inspect and, if necessary, replace the transmissions, free of charge. Owner notification letters were mailed April 25, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S06.
FORWARD COLLISION AVOIDANCE: SENSING SYSTEM: CAMERA · 22V334000
2022-05-13
Ford Motor Company (Ford) is recalling certain 2022 Mustang vehicles equipped with an Image Processing Module A (IPMA) or forward-facing camera. The camera is misaligned to the vehicle, resulting in the camera not functioning as intended.
Consequence: A front-facing camera that is not functioning properly may restrict or disable certain features including Pre-Collision Assist, Adaptive Cruise Control, Lane Keeping System, Driver Alert, and Auto High Beam Control, increasing the risk of a crash.
Remedy: Dealers will realign the front-facing camera, free of charge. Owner notification letters were mailed on May 27, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S34.
AIR BAGS:KNEE BOLSTER · 22V083000
2022-02-16
Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang vehicles. An insufficient weld on the front passenger knee air bag may result in an improper air bag deployment.
Consequence: An improper air bag deployment can increase the risk of injury during a crash.
Remedy: Dealers will replace the front passenger knee air bag, free of charge. Owner notification letters were mailed on March 8, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S07.
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🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.