Serious safety flaw triggers global Mustang Mach-E recall

The potentially fatal nature of power-operated door technology has been emphasised by Ford Australia this week, with every example of the fully electric Mustang Mach-E recalled.

It follows carsales’ exclusive award-winning report in February that exposed the dangers of power-operated doors when a vehicle’s ancillary 12-volt power is cut, and led to industry action from independent safety authority, ANCAP.

The tech, often marketed as a convenience feature for car buyers as well as aiding vehicle aerodynamics, has become common in modern vehicles including many EVs, and can be found Down Under in cars like the Tesla Model 3 and Model Y, XPeng G6, Zeekr X, Chevrolet Corvette, and Ford Mustang Mach-E, among others.

Last month, Ford globally acknowledged the issue when it recalled almost 200,000 units of the Mach-E in the US, warning of “serious injury, especially in hot weather” if the 12V battery discharges below 8.4V, which could cause the electrically operated doors to malfunction, potentially trapping vehicle occupants.

Now, the issue has hit home, with Ford Australia this week recalling a total of 1234 examples of the electric Mustang Mach-E, all built between 2023-2025.

According to the safety notice, published on the federal government’s Vehicle Recalls website, a software issue is to blame with Ford stating:

“Due to a software issue, if the occupants exit the driver and/or front passenger doors using the interior mechanical release handles when the 12V battery is discharged and the doors are in lock status, the doors may remain locked when they are re-closed. If this occurs, the key fob, interior and exterior handles will not unlock the doors.”

Ford says in the event of an emergency, an occupant who remains inside a locked vehicle and unable to use an inside door release handle (such as a baby or young child) may not be able to exit or be retrieved from the vehicle, increasing the risk of injury or death to vehicle occupants.

The Mustang Mach-E has a mechanical back-up to exit the vehicle cabin in the event of power loss, however anyone outside the vehicle trying to get in – via its external push-button electric door releases – to retrieve a baby for example, won’t be able to open the doors without a 12V power source.

In the US, Ford’s recall notice posted to the National Highway Traffic Safety Administration (NHTSA) site, reads: “‘In the event of an unexpected 12V battery discharge below 8.4V at key-off, side door electronic latches (e-latches) retain their lock/unlock status at time of 12V discharge. If the driver or front passenger exit the front doors using the mechanical inside release handles, the doors will remain locked when they are re-closed if the e-latches were locked at the time of 12V battery discharge. This may result in an unexpected lock-out condition for the driver and front passenger without the ability to immediately re-enter the vehicle”. Owners of the affected vehicles will be contacted in writing requesting they contact an Authorised Ford Dealer to have their vehicle rectified, free of charge.

Join the conversation at our Facebook page
Or email us at editor@carsales.com.au