Ford Mustang Mach-E Faces Another Major Recall: Doors Could Trap Occupants Inside Amid Battery Glitch
In a fresh blow to Ford’s electric ambitions, the Mustang Mach-E is back in the recall spotlight—this time with a chilling safety flaw that could lock passengers inside the vehicle during emergencies. Affecting nearly 200,000 units from 2021 to 2025, the issue stems from a low 12-volt battery discharge that cripples the electronic door latches, prompting a nationwide stop-sale and software scramble just as summer road trips heat up.
The recall, flagged under NHTSA campaign 25V404000 (Ford’s 25S65), targets 197,432 Mustang Mach-E crossovers built between February 24, 2020, and June 3, 2025. At the core: An unexpected drain on the 12-volt battery—separate from the main high-voltage pack—halts power to the e-latch system, causing doors to freeze in their last state (locked or unlocked). If they lock while someone’s inside, escape becomes a nightmare, especially for backseat riders without manual overrides. Ford’s probe, spanning months, traced it to outdated Powertrain Control Module (PCM) software that fails to sustain 12V support post-“key-off,” a glitch exacerbated by extreme cold or prolonged inactivity.
This isn’t the Mach-E’s first rodeo—it’s the latest in a string of setbacks for Ford’s EV darling. Just last month, over 21,000 2025 models (including 808 Mach-Es) were yanked for faulty headlights that could flicker out, hiking crash risks. March brought a contactor overheat fix for 2021-2022 units, potentially stalling the car mid-drive. And in June, a niche park rod assembly recall hit a handful of 2025s, risking unintended rollaways. Globally, the tally tops 300,000 for this door drama alone, with no reported crashes or injuries yet—but experts warn that’s small comfort for owners sweating entrapment scenarios.
The remedy? A free over-the-air (OTA) or dealer-installed software update to the PCM and Secondary On-Board Diagnostic Control Module C (SOBDMC), ensuring sustained 12V flow and manual latch backups. Notifications hit mailboxes starting June 23, 2025, with VIN checks live since mid-June. In the interim, Ford’s slapped a stop-sale on unsold inventory, halting demos and deliveries until patched— a gut punch as May sales climbed 11% year-over-year to 4,724 units. Owners can manually escape by double-pulling interior handles (first to unlock, second to pop), but Ford urges vigilance: Park with doors ajar if battery warnings flash.
Safety advocates are piling on. Consumer Reports slammed the e-latch dependency as “overly reliant on tech,” urging NHTSA scrutiny of EV door designs across brands. Ford Authority’s Brett Tumas called it a “design blunder” echoing early Mach-E teething pains, like the 2021 contactor woes. On X, owners vent frustration: One viral post from @MachEClub racked up 2.5K likes—”Another recall? Sold my 2021 after the battery scare; now regretting not going Tesla.” Threads buzz with workarounds, like trickle chargers, but dealership gripes dominate: “Stop-sale killing Q3 quotas,” per a Detroit News dealer quote.
For U.S. EV shoppers, this recall ripple hits hard. Economically, it dents Ford’s $50B EV push—Mach-E sales (19,258 through May) lag Tesla’s Model Y but outpace Hyundai Ioniq 5—potentially hiking insurance premiums 5-10% amid repair backlogs. Lifestyle snags? Families eyeing the 300-mile range and $36K starting price (post-employee discounts) now face “trapped kid” nightmares, especially in crashes where seconds count. Politically, it fuels Biden-era EV subsidy debates, with Republicans decrying “rushed green tech” flaws. Tech-savvy perks shine through, though: OTA fixes mean no tow-truck drama, unlike legacy gas guzzlers.
| Recall | Issue | Affected Models | Fix | NHTSA ID |
|---|---|---|---|---|
| Door Entrapment (June 2025) | Low 12V battery locks e-latches | 2021-2025 (197K US) | Software update | 25V404000 |
| Headlights (Aug 2025) | Malfunction risk | 2025 (808 Mach-E) | Module replacement | N/A |
| Contactor Overheat (Mar 2025) | Power loss on fast charge | 2021-2022 | Software update | 25S14 |
| Park Rod (June 2025) | Rollaway risk | 2025 (small batch) | Assembly swap | N/A |
Ford insists no fires or wrecks tied to these, but the pattern’s troubling—five major actions in 2025 alone.
Looking ahead, patches roll out by late July, but with Q3 sales slumping, expect rebates or incentives to lure buyers back. If Ford irons out these gremlins, the Mach-E could reclaim its EV SUV throne; for now, it’s a cautionary tale in battery-powered bliss.
By Sam Michael
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