NHTSA complaint #11472791

Owner complaint summary

The HVBJB subassembly in ALL Ford Mach-e vehicles has known defects with under-designed main contactors that are known to fail under normal charging and driving conditions as outlined in current open Ford recall notice for my vehicle 22S41. Unfortunately, the internal damage to contactors is not visible externally, and warning notices on display only after damage has occurred, and can result in sudden loss of propulsion power at highway speed, loss of power steering, power brakes, and failure of other 12v systems due to failure to charge the 12v battery properly after contactors are damaged. Less catastrophic results can include failure to start; which can strand driver's and passengers in remote areas, bad weather conditions, as well as cause loss of use for weeks due to delays in replacement parts and local Dealerships needing equipment and training to effect removal/replacement of faulty unit with a new HVBJB having re-designed components capable of meeting safety and normal usage requirements of Mach E owners.? ? My complaint is that Ford's recall notice 22S41 is a software-only attempt to prevent future damage, and does not require removal of the part(s) which are KNOWN TO FAIL to be replaced with the re-designed components which are available, and have been used to repair failures under warranty. I have no way of inspecting the original equipment to evaluate current condition; and failure can result in sudden and unexpected loss of power, steering, and braking as well as potentially stranding me in unsafe conditions unable to re-start my vehicle.? ? I would like to see NHTSA require that the Ford recall include both improved software AND removal/replacement of the HVBJB sub-assembly with the new appropriately specified parts.? Failure examples: https://www.macheforum.com/site/threads/-post-battery-contactor-recall-first-junction-box-failure-.19209/ and https://www.macheforum.com/site/threads/post-recall-software-hvbjb-failure.19396/