California Lemon Law « California Lemon Law blog

The 2024 Mazda CX-90 Plug-in Hybrid Electric Vehicle (PHEV) is facing serious concerns from owners, with a reported 130 complaints, 10 recalls, and 303 manufacturer communications. As this model hits the market, many drivers are voicing their frustration over problems that range from safety-critical issues to major mechanical failures. The list of concerns brings into question whether some of these vehicles could qualify for a buyback under California’s Lemon Law. Here’s an in-depth look at the problems plaguing the 2024 CX-90 PHEV.

Top Complaints About the 2024 Mazda CX-90 PHEV

Consumer reports and complaints have highlighted four major areas of concern: forward collision avoidance, engine performance, electrical systems, and steering. These issues are not just minor inconveniences; they could pose significant safety hazards for drivers and passengers.

Forward Collision Avoidance: Numerous drivers have reported malfunctioning collision-avoidance systems, with false positives causing the brakes to activate unexpectedly. The risk of being rear-ended due to this sudden and unnecessary braking is a valid concern, especially on busy roads or highways.
Engine Issues: Many drivers have experienced engine problems, with some vehicles failing to restart after the i-stop feature engages, and others reporting a complete shutdown while in motion. This kind of unreliability in the engine system poses a clear danger, especially at high speeds.
Electrical Problems: Complaints about electrical malfunctions are widespread. The Dash Electrical Supply Unit (ESU) has been known to fail, affecting vital functions like the defroster, seat belt warnings, and battery cooling systems. Given the reliance of PHEVs on complex electrical systems, these issues are alarming and inconvenient.
Steering Concerns: A sudden loss of power steering assist is a particularly dangerous defect, making it difficult for drivers to control the vehicle. This kind of failure can occur without warning, putting both the driver and surrounding traffic at risk.

Recalls Highlight Safety and Reliability Concerns

The 2024 Mazda CX-90 PHEV has been subject to a staggering 10 recalls, indicating widespread problems that extend beyond individual cases. Here are some of the most notable recalls:

Engine Restart Failures: The i-stop feature, which automatically shuts off the engine to save fuel when idling, may prevent the engine from restarting, leading to potential stranding.
High-Voltage Battery Cooling System Issues: Faulty software in the ESU may lead to critical functions, including battery cooling and safety alerts, failing during startup.
PCM and ECM Software Malfunctions: Problems with the powertrain and engine control modules can illuminate warning lights and result in a sudden loss of drive power.
Inverter Software Errors: In plug-in hybrid models, improper software may lead to a total power loss when driving in electric mode.
Sudden Braking: The automatic braking system has a tendency to activate unexpectedly, posing a serious collision risk.
Power Steering Failures: An assembly issue with the worm gear can cause power steering assist to be lost without warning, making the vehicle difficult to steer.
Camera Malfunctions: Rear view and side cameras may not display properly due to software errors, which is a clear safety compliance issue.
Unexpected Engine and Motor Shutdown: Critical errors in the hybrid system software can cause both the engine and electric motor to shut down unexpectedly.
Pedestrian Warning Sounds: Missing software in the AVAS amplifier can result in incorrect pedestrian alert sounds, failing to meet federal safety standards for hybrid and electric vehicles.

California Lemon Law: What You Need to Know

California has some of the strongest Lemon Law protections for consumers. If your vehicle has repeated, unresolved problems that impair its use, safety, or value, you may be entitled to a buyback or replacement. Under the California Lemon Law, a car manufacturer must either replace your vehicle or refund your money if they cannot fix a substantial defect within a reasonable number of attempts.

So, what counts as a substantial defect? Issues that compromise your safety or significantly impact the car’s performance typically qualify. For instance, if your 2024 Mazda CX-90 PHEV loses power while driving, suddenly engages the brakes, or suffers from major electrical failures, these could be considered substantial defects.

If you’ve taken your vehicle in for multiple repairs for the same issue without a permanent fix, you might have grounds for a Lemon Law claim. It’s important to keep detailed records of all service visits, recall repairs, and communication with Mazda to strengthen your case.

Next Steps for Owners

If you’re dealing with repeated, unresolved issues with your 2024 Mazda CX-90 PHEV, consulting with a Lemon Law attorney can help clarify your options. California’s Lemon Law is designed to protect you from being stuck with a faulty vehicle. Given the ongoing recalls and widespread complaints, many owners may find themselves in a position to take advantage of these consumer protections.

The Hyundai Santa Fe is a popular choice for families and adventurers alike, known for its spacious design, modern features, and reasonable price point. However, recent models (2021-2024) have experienced a series of issues that have frustrated owners and raised safety concerns. These common problems affect Santa Fe vehicles with GDI engines.

Common Issues Affecting the 2021-2024 Hyundai Santa Fe

Fuel Injector Problems Leading to Stalling
A major concern for many Santa Fe owners is the vehicle’s fuel injector system. Faulty fuel injectors can cause the engine to stall unexpectedly, especially in models with GDI (Gasoline Direct Injection) engines. These issues have led to numerous complaints of the vehicle stalling while driving, creating hazardous situations on busy roads.
Loss of Power
Some owners report a sudden loss of power while driving, particularly when accelerating or maintaining speed on the highway. This loss of power can be alarming and dangerous, especially in situations where acceleration is necessary, such as merging or overtaking. Many drivers have reported that their Santa Fe either stalls entirely or hesitates significantly before regaining power, often triggering check engine or warning lights.
Persistent Check Engine Light
For Santa Fe models across 2021-2024, the check engine light has become a frequent visitor. Many owners report that the light comes on without clear resolution, even after multiple trips to the dealership. While the check engine light could signify any number of issues, the combination of repeated lights and related powertrain issues has led to frustration and concerns about reliability.

Complaints and Recalls for Each Model Year

2021 Hyundai Santa Fe

Owners of the 2021 model have raised concerns about fuel system problems, including fuel leaks at the pipe connection and improperly tightened fuel pipes. Powertrain complaints are also prevalent, with owners describing issues such as failure to accelerate and hesitation while driving. Recalls include:

Tow Hitch Harness Fire Hazard: Due to water accumulation, an electrical short could lead to a fire.
Loss of Drive Power: A transmission oil pump malfunction can cause total power loss.
Inadequate Windshield Bonding: Improper bonding during manufacturing may cause the windshield to detach in a crash.

2022 Hyundai Santa Fe

The 2022 Santa Fe has seen similar powertrain issues, with some owners reporting a sudden inability to accelerate and warning lights like “Check Hybrid System.” The “phantom braking” issue has also emerged, where the emergency braking system activates without reason, nearly causing accidents. Recalls for the 2022 model include:

Tow Hitch Harness Fire Hazard
Loss of Drive Power
Turbocharger Oil Supply Pipe Leak: A cracked oil supply pipe could lead to leaks in the engine compartment.

2023 Hyundai Santa Fe PHEV

In the 2023 plug-in hybrid models, forward collision avoidance issues have led to abrupt braking in traffic. Complaints also include poor acceleration response, with significant delay or lag from the time the accelerator is pressed to when the vehicle actually moves. Key recalls include:

Tow Hitch Harness Fire Hazard
Seat Belt Pretensioners May Explode: This recall affects the front seat belt pretensioners, which may explode upon deployment in a crash.

2024 Hyundai Santa Fe

For the latest 2024 model, powertrain and electrical issues are significant. Some drivers report the vehicle losing motive power and experiencing flickering dashboard screens. Complaints include blacked-out instrument panels, “Transmission System Check” warnings, and persistent audio issues that continue even when the vehicle is off. Recalls for this model include:

Unintentional Airbag Deployment or Deactivation: Damaged wiring harnesses can lead to unintended airbag activation or deactivation.
Vehicle Roll Away from Software Error: A transmission software error may result in a roll-away when the vehicle is parked.
Obstructed Rear-View Camera Image: A trailer parking assist message may obstruct the rear-view camera, violating rear visibility standards.

Should You Be Concerned?

These issues have led to frustration for many Hyundai Santa Fe owners. If you’re experiencing any of the above problems, it’s essential to address them promptly for your safety. Keep an eye out for any recalls or technical service bulletins (TSBs) from Hyundai, and report any persistent issues to your dealer.

What’s Next?

The 2021-2024 Hyundai Santa Fe offers many attractive features but has also faced considerable challenges, particularly with its powertrain and fuel injector systems. If you’re dealing with ongoing issues, it’s crucial to know your rights, especially if repairs have been ineffective. Lemon laws may protect you if your vehicle has recurring problems that affect its performance or safety. Consider consulting with a lemon law professional to discuss options if repairs haven’t resolved the issue.

Owning a car should be about convenience and freedom – not worry over performance and safety. If you’re having trouble with your Santa Fe, stay informed, stay safe, and know your options.

The Volkswagen ID.4 SUV represents the German automaker’s entrance into the growing electric vehicle (EV) market. Launched with the promise of combining the brand’s legendary driving dynamics with cutting-edge EV technology, the ID.4 aims to provide a sustainable yet practical driving experience. However, as with many new models, especially those pioneering new technologies, the ID.4 has faced its share of teething troubles. This article will delve into the common problems reported by ID.4 owners and explain how these issues could potentially classify your vehicle as a lemon under the California Lemon Law. We’ll also highlight the importance of seeking assistance from a lemon law attorney if you find yourself grappling with persistent vehicle issues.

Common Volkswagen ID.4 Problems

1. Charging Issues

Many ID.4 owners have reported difficulties with charging their vehicles. Problems range from slow charging speeds to the car not charging at all. Some users have encountered issues with the compatibility of their ID.4 with various public charging stations, leading to inconvenience and frustration.

2. Software Glitches

The ID.4’s infotainment system and other software-driven features have been a source of concern for some drivers. Complaints include unresponsive touchscreens, malfunctioning navigation systems, and intermittent connectivity issues with smartphones. These software bugs can detract from the overall user experience and disrupt daily usage.

3. Battery Performance

Some ID.4 owners have reported inconsistent battery performance, including unexpected drops in range and inaccurate range estimates. Such issues can severely impact the reliability of the vehicle, especially for long-distance travel.

4. Build Quality

Although Volkswagen is renowned for its build quality, some ID.4 owners have experienced issues with fit and finish. Reports include problems with door alignment, rattling noises from the cabin, and malfunctioning interior components. These issues, while sometimes minor, can affect overall satisfaction with the vehicle.

5. Electrical System Faults

Electrical system faults have also been reported, with owners experiencing warning lights and system errors. These faults can be unsettling and sometimes necessitate multiple visits to the dealership for resolution.

When Is Your Vehicle a Lemon?

A vehicle is generally considered a “lemon” if it has significant defects that affect its use, value, or safety, and these defects persist despite multiple repair attempts. Under California law, a vehicle is presumed to be a lemon if:

The manufacturer has made at least two attempts to repair a warranty problem that could result in death or serious injury if the vehicle is driven.
The manufacturer has made at least four attempts to fix the same warranty problem.
The vehicle has been out of service for more than 30 days (not necessarily consecutive) for warranty issues.

Understanding the California Lemon Law

The California Lemon Law, officially known as the Song-Beverly Consumer Warranty Act, provides robust protections for consumers who purchase or lease new vehicles. The law mandates that if a manufacturer cannot repair a vehicle to conform to its warranty after a reasonable number of attempts, the manufacturer must either replace the vehicle or refund the purchase price, minus a usage fee.

Benefits of the California Lemon Law

Consumer Protection: The law protects consumers from being stuck with a defective vehicle.
Replacement or Refund: Consumers are entitled to a replacement vehicle or a refund, ensuring they receive the value they paid for.
Legal Support: Consumers can recover legal fees if they prevail in a lemon law claim, making it financially feasible to pursue legitimate claims.

The Importance of a Lemon Law Attorney

Navigating the intricacies of the California Lemon Law can be challenging, and manufacturers often have significant legal resources at their disposal. Here’s why hiring a lemon law attorney is a smart move:

Expertise: Lemon law attorneys have specialized knowledge of consumer protection laws and can effectively navigate the legal process.
Maximized Compensation: An attorney can help ensure you receive the maximum compensation you are entitled to, including potential incidental and consequential damages.
No Upfront Costs: Many lemon law attorneys work on a contingency basis, meaning they only get paid if you win your case.

Conclusion

The Volkswagen ID.4 SUV, while a promising entry into the electric vehicle market, has faced several common problems reported by owners. If you find yourself repeatedly dealing with these issues, your vehicle might qualify as a lemon under the California Lemon Law. Seeking the assistance of a lemon law attorney can provide the expertise and support needed to navigate this legal landscape and ensure you receive fair treatment. Remember, consumer protection laws are there to safeguard your rights and ensure you get the quality you paid for in your vehicle purchase.

Ford Issues Recall for Certain 2024 Mustang Models Due to Under Hood Fire Risk

Ford Motor Company (Ford) have identified a problem that could potentially lead to under hood fires in certain 2024 Mustang vehicles. Owners of the affected vehicles will receive notification letters with detailed instructions on how to get the necessary repairs. These letters are expected to be mailed by June 17th, 2024.

Discovery of the Problem

Ford became aware of the issue in April 2024 after receiving two reports of under hood fire allegations in 2024 Mustang models equipped with manual transmissions. Upon receiving these reports, Ford’s Critical Concern Review Group (CCRG) promptly conducted inspections of both vehicles to determine the root cause of the fires. Following their investigation, the company decided to issue a recall to address the identified defect.

Details of the Defect

The defect report indicates that the vehicle’s clutch pressure line may not be properly secured to the vehicle’s firewall stud. An improperly retained clutch pressure line can come into contact with hot exhaust components and potentially melt, leading to brake fluid leakage. Although this leakage does not affect the brake system’s fluid volume or functionality, it can significantly impact the clutch system. Specifically, the defect can result in an inability to change gears, and in certain situations, the engine may stall when the throttle is released. Moreover, if the leaked brake fluid accumulates near a hot surface, there is a risk of smoke and an under hood fire, posing a serious safety hazard.

Recall Details and Repair Process

To address this issue, Ford dealers will inspect the clutch pressure line and perform necessary repairs to ensure it is properly retained. The recall has been assigned Ford’s internal number 24S36, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-394.

What Should Owners Do?

If you own a 2024 Mustang, especially one with a manual transmission, it is crucial to stay informed about this recall. Keep an eye out for the notification letter from Ford, which will provide specific instructions on how to proceed with the necessary repairs. In the meantime, if you experience any issues with your vehicle’s clutch or observe any unusual smoke from under the hood , contact your local Ford dealer for repairs, immediately.

Could Your Vehicle Be A Lemon?

The Lemon Law is a consumer protection statute designed to provide relief to car buyers who purchase vehicles that fail to meet quality and performance standards. It ensures that consumers can seek recourse if their new car has serious defects that the manufacturer cannot fix within a reasonable number of attempts. An essential aspect of leveraging the Lemon Law is maintaining accurate and detailed paperwork whenever your vehicle undergoes repairs. This documentation includes repair orders, work performed, dates, and technician notes. Accurate records are crucial because they serve as evidence of the recurring issues and the attempts made to resolve them, which can substantiate a Lemon Law claim. Without proper documentation, proving that your vehicle qualifies as a “lemon” can be challenging, potentially hindering your ability to receive a replacement, refund, or compensation.

In a recent announcement, Ford has highlighted a critical concern affecting a specific subset of its 2023 Ford Explorer vehicles. The issue revolves around the right-front lower fastener connecting the steering knuckle and strut, which may either be loose or missing altogether. This problem can have significant repercussions on the vehicle’s performance and safety.

A loose or missing connection between the knuckle and strut can lead to improper tire alignment, potentially causing steering pulls or requiring increased steering effort. Moreover, the proximity of the brake hose to the tire in this compromised setup poses an additional risk. If the hose comes into contact with the tire, it may sustain damage resulting in a brake fluid leak, ultimately leading to a loss of braking ability. These circumstances significantly elevate the likelihood of a crash, underscoring the severity of the situation.

Upon receiving a report of a missing fastener,Ford’s Critical Concern Review Group (CCRG) initiated an investigation at the beginning of January 2024. The Plant Vehicle Team (PVT) at the Assembly Plant promptly identified the issue during a routine warranty claim review. Further analysis revealed that the primary double spindle fixture tool responsible for securing the right front knuckle-to-strut fasteners was offline for repairs during a specific period. This temporary setback affected a limited number of vehicles, with Ford confirming that out of 121 Explorer rotations, only one vehicle was found to have a missing fastener. Nonetheless, the company is taking proactive steps to address the concern.

While Ford has not identified any vehicle owner questionnaires (VOQs) related to this condition, it’s crucial for affected vehicle owners to remain vigilant. Signs of potential issues include a visually detectable tire leaning inward at the top or changes in steering effort or pull. Additionally, if there are any indications of tire contact with the strut or spring seat, such as abrasion damage or a burning smell, prompt action is necessary.

In response to this concern, Ford has announced a field action to have the affected vehicles inspected. Dealers will thoroughly examine the fasteners and take appropriate measures, such as tightening or installing them as needed, to rectify the issue. Affected vehicle owners can reference Ford’s recall number 24S04 and the corresponding NHTSA campaign number 24V-091 for further information and to schedule inspections.

Importance of Keeping Records for Lemon Vehicles:

Maintaining detailed records of repairs and maintenance for your vehicle is essential, especially if you suspect that your vehicle might be a lemon. Lemon laws vary by jurisdiction, but generally, they provide recourse for consumers who have purchased a defective vehicle that the manufacturer has failed to repair adequately within a reasonable number of attempts.

Keeping comprehensive records serves several purposes. Firstly, it provides documentation of the issues you’ve experienced and the attempts made to address them, which can be crucial evidence if you need to pursue legal action under lemon laws. Additionally, it helps establish a pattern of recurring problems, strengthening your case for a vehicle replacement or refund.

Furthermore, detailed records can expedite the repair process by providing technicians with essential information about past issues and repairs. This can help diagnose and resolve problems more efficiently, minimizing inconvenience for you as the owner.

In summary, maintaining thorough records of repairs and maintenance is not only good practice for vehicle ownership but can also be invaluable if you find yourself grappling with a lemon. By documenting issues and repairs diligently, you empower yourself to assert your rights as a consumer and seek appropriate recourse if necessary.

The Jeep Wrangler 4XE plug-in hybrid has faced a series of challenges that have left many owners questioning the reliability of their vehicles. Reports from owners highlight a range of issues, from stalling engines that cannot be restarted to transmission errors, battery defects, and more serious safety concerns.

One common complaint among Wrangler 4XE owners is the vehicle’s tendency to stall unexpectedly, leaving drivers unable to restart the car. This issue is not just inconvenient but poses a significant safety risk, especially if it occurs in traffic or remote areas. Additionally, there have been reports of defective batteries and blown fuses, further contributing to the vehicle’s unreliability.

Transmission problems are another significant issue, with some owners experiencing leaks and errors, alongside instances where the shifter becomes stuck in park, rendering the vehicle immobile. Warning lights, such as the check engine light and power steering light, frequently accompany these mechanical failures, along with messages indicating the need to “Service Electronic Stability.”

Charging issues have also been a point of frustration. Errors like “Service Charging System” have been reported, alongside malfunctions in the Power Inverter Module (PIM), further complicating the ownership experience. In some cases, these electrical issues lead to a complete loss of power, preventing the vehicle from starting.

More alarming are reports of oil leaks from the exhaust and rear undercarriage, with one vehicle diagnosed with a bad pinion seal on the rear axle at merely 241 miles on the odometer. The recurrence of such leaks, accompanied by smoke and the potential risk of fire, underscores the severity of the Wrangler 4XE’s problems.

The erratic behavior of the vehicle’s transmission and propulsion systems, including sudden stops in the middle of highways and unintended acceleration that has led to property damage, raises significant concerns about the safety and reliability of the Jeep Wrangler 4XE.

For owners facing these daunting issues, California’s Lemon Law provides a beacon of hope. This law is designed to protect consumers who have purchased or leased new vehicles covered by a manufacturer’s new vehicle warranty. If a vehicle proves to be defective and cannot be repaired after a reasonable number of attempts, the manufacturer is required to either replace the vehicle or refund the purchase price to the consumer.

Under the California Lemon Law, owners of the Jeep Wrangler 4XE experiencing repeated failures that substantially impair the vehicle’s use, value, or safety may be entitled to relief. It’s essential for affected owners to keep detailed records of all repairs and attempts made to address the issues, as these documents will be crucial in pursuing a lemon law claim.

The myriad of problems faced by Jeep Wrangler 4XE owners highlights the challenges in the automotive industry’s shift towards electrification, especially in models that are expected to perform under the demanding conditions for which Jeeps are renowned. For those grappling with these defects, understanding and utilizing the protections offered by the Lemon Law can provide a pathway to resolution and ensure that manufacturers are held accountable for the reliability and safety of their vehicles.

Automobile Rebuild Tites

Vehicles with rebuilt titles in the United States represent a unique category in the automotive market. Understanding what a rebuilt title is, its implications, and the pros and cons of purchasing such vehicles is crucial for any potential buyer or current owner.

What is a Rebuilt Title?

A rebuilt title is assigned to a vehicle that was previously deemed a total loss by an insurance company due to extensive damage or theft and then repaired to a roadworthy condition. This title indicates that the vehicle has been restored after significant damage.

How a Vehicle Gets a Rebuilt Title

Damage and Insurance Assessment: Initially, a vehicle is given a salvage title when it’s considered a total loss by an insurance company, typically due to severe damage, flood, fire, or theft.
Repair and Restoration: The vehicle is then repaired, often by a private individual or a repair facility.
Inspection: After repairs, the vehicle undergoes a state-mandated inspection to ensure it meets safety standards.
Rebranding as Rebuilt: Once it passes inspection, the vehicle’s title is rebranded from salvage to rebuilt.

Identifying a Vehicle with a Rebuilt Title

The title document itself will clearly state if it is a rebuilt title. Additionally, vehicle history report services can provide this information based on the vehicle identification number (VIN).

Impact on Automobile Insurance

Limited Insurance Options: Many insurers are hesitant to cover rebuilt title cars or offer limited policies excluding collision and comprehensive coverage.
Higher Premiums: Those that do offer full coverage might charge significantly higher premiums due to the perceived higher risk.

Pros and Cons of Buying a Rebuilt Title Vehicle

Pros

Documented Repair Work: Sellers of rebuilt title cars often provide detailed documentation of repairs, offering more insight into the vehicle’s condition than typical used car transactions.
Significant Discounts: These vehicles are generally much cheaper, with potential discounts up to 50% compared to cars with clean titles.

Cons

Safety Risks: There’s an inherent risk in the vehicle’s safety standards, as the extent and quality of repairs can vary.
Limited Insurance Coverage: Difficulty in securing comprehensive insurance coverage is a significant drawback.
Financing Challenges: Most major banks are reluctant to finance vehicles with rebuilt titles.
Voided Warranty: Manufacturer warranties are typically voided once a vehicle is marked as salvage or rebuilt.
Low Resale Value: These vehicles have a lower resale value and may be challenging to sell, as some dealerships avoid buying them.

Owning a vehicle with a rebuilt title can significantly impact the applicability and process of invoking the California Lemon Law. This law is designed to protect consumers who purchase or lease new vehicles with substantial manufacturing defects. However, when it comes to vehicles with rebuilt titles, the situation becomes more complex. Typically, these vehicles are excluded from coverage under the California Lemon Law because they are not new and have been extensively repaired after being deemed a total loss. The law primarily covers vehicles under the original manufacturer’s warranty, which is often voided in the case of a rebuilt title. Additionally, the history of significant damage and subsequent repairs makes it challenging to attribute any new defects directly to the manufacturer’s responsibility, a key criterion under the Lemon Law. As a result, owners of vehicles with rebuilt titles may find it extremely difficult, if not impossible, to seek remedy under this law for any issues that arise with their vehicle.

Vehicles with rebuilt titles present a mixed bag of opportunities and challenges. While they offer an affordable option with potentially well-documented repair histories, the drawbacks in terms of safety, insurance, financing, warranty, and resale value are significant. It’s essential for buyers to weigh these factors carefully, conduct thorough research, and consider their willingness to accept the risks associated with a rebuilt title vehicle.

Certain 2021-2022 Ford Mustang Mach-E cars might face a power problem due to an overheated high voltage battery contactor, potentially leading to an increased risk of accidents.

In June 2022, Ford’s Field Review Committee (FRC) gave the green light to a Field Service Action (FSA) named 22S41, specifically designed to tackle concerns regarding the overheating of the high voltage battery main contactor in select 2021-2022 Mustang Mach-E vehicles. To fix this issue, dealers updated the software for the Secondary On-Board Diagnostic Control Module (SOBDMC) and the Battery Energy Control Module (BECM). The enhanced SOBDMC software keeps an eye on the contactor’s temperature and smartly reduces the battery’s power output to prevent further damage. Meanwhile, the upgraded BECM software checks the contactor’s resistance to identify any damage, then it generates a diagnostic trouble code (DTC) and lowers the vehicle’s power to avoid more harm.

At the time of approving this FSA, Ford’s Critical Concern Review Group (CCRG) and Electrical Propulsion Engineering (EPE) teams found the software updates for BECM and SOBDMC to be a suitable way to minimize the safety risks linked to power loss. The software update, by monitoring contactor resistance, warns customers if the resistance exceeds a certain limit. Alongside the warning, the software reduces power to prevent further contactor damage and the associated power loss risk. Even with the reduced power, customers can safely accelerate to highway speeds. This approach was also reviewed with the National Highway Traffic Safety Administration (NHTSA).

In June 2022, Ford Motor Company decided to issue a safety recall (NHTSA Recall 22V-412) for 48,924 model year 2021-2022 Ford Mustang Mach-E vehicles produced between May 27, 2020, and May 24, 2022. This recall was prompted by concerns about high voltage battery contactors overheating, primarily due to direct current (DC) fast-charging and repeated full-throttle pedal events. This overheating could lead to arcing or deformation of the electrical contact surfaces. If this occurs, the contactor could either remain open or get welded shut. An overheated contactor that opens while driving may lead to an immediate loss of power without re-engagement.

Following consumer complaints, the Office of Defects Investigation (ODI) initiated a Recall Query (RQ) for 2021-2022 Ford Mach-E vehicles included in Recall 22V-412. These vehicles had previously received a remedy involving a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to protect the contactor, as well as a Battery Energy Control Module (BECM) software update to monitor contactor resistance and reduce vehicle power in case of an overheated contactor.

To address this issue, dealers will replace the high voltage battery junction box. This recall is identified by Ford as 23S56, and the corresponding NHTSA campaign number is 22V-687. Vehicles included in this recall that were previously repaired under recall 22V-412 will need to have the new remedy completed.

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