2022 Ford Mustang Mach-E Brakes Problems

Parking brake malfunction indicated. Ford CSP 22P31 covers repair of the issue for vehichles with a manufacture date before 3/15/22. My vehicle reached the US on 6/22/22. Ford has offered to cover a small part of the repair, but won't include me in the fix due to manufacture date. So Ford ended the program, NEVER FIXED THE ISSUE, and now won't offer to repair my car.

Vehicle: 2022 Ford Mustang Mach-E Mileage at failure: ~36,800 miles Complaint Description: The left rear electronic parking brake (EPB) wiring harness/connector failed, resulting in a parking brake fault and abnormal braking behavior. This component is not a wear-and-tear item and is located in a fixed, protected area of the vehicle. It is not subject to routine maintenance or driver interaction. The failed wiring harness was inspected by an authorized Ford dealership and is available for further inspection upon request. This failure put safety at risk because the electronic parking brake is a safety-critical braking system. The fault created uncertainty regarding proper engagement and release of the parking brake, increasing the risk of unintended vehicle movement when parked and reduced confidence in braking reliability while driving. The problem was confirmed and diagnosed by a Ford dealership, which determined the wiring failure developed over time due to moisture intrusion and corrosion, not misuse, accident damage, or normal wear. The vehicle and component were inspected by an authorized Ford dealership. Ford Motor Company reviewed the repair documentation through Ford Customer Care but did not dispute the diagnosis. The component has not been inspected by police or insurance representatives. A parking brake fault warning message appeared shortly before diagnosis, accompanied by abnormal braking behavior. There were no prior accidents, vehicle modifications, or external damage related to the failure. This failure is identical to a known defect already acknowledged by Ford in Customer Satisfaction Program 22P31, which covers EPB wiring harness connector failures on other 2021–2022 Mustang Mach-E vehicles. Although my VIN was excluded, the same non-wear safety defect occurred within the same model year, indicating a broader safety concern beyond the original VIN population.

After 22,207 mi, the right rear wheel unit started making a clunking similar to a flat tire. I looked online and found TSB 22-2023 which states that a common problem with the Mach E one pedal driving is brake pad material gets fused to the rotor. I took it in for repair and the brakes are out of warranty after 18000mi. Average life of brake rotors FOR CARS THAT USE THEIR BRAKES is 30,000-70,000mi. If Ford knowingly continues to use brake components that become faulty and fail after such.a short time on cars that don’t regularly use brakes, this problem could cause serious brake failure in cases of emergent braking. One pedal users would not know their brake pads had fused to the rotors until too late and the braking system fails when they need it.

The vehicle was delivered [XXX], its an EV and does probably 70% highway/30% city driving. As an EV is on "one pedal" mode exclusively to use the motor to brake the vehicle and regenerate charge to the battery so we rarely use the actual brakes. at 18k mile we notices when the brakes were applied the vehicle and steering wheel shock, we took the car in for service and the front brake rotors were re-surfaced as per Metro Ford in Miami, FL. We noticed again at 22k miles and then Metro Ford in Miami, FL replaced the front rotors as they could not be resurfaced since they were already resurfaces once and would have been out of spec. At 28k miles we notices again, we took it again to Metro Ford in Miami, FL and they said it was cause by brake pad glazing and pad needed to re-surfaced and this time also resourced the rear rotors. All this is been done under warrantee with the exception of replacement of front pads in the last repair as Metro Ford in Miami, FL considered them a "wear" item (even with clear history with brakes) the approximate cost was $427. I believe there is clearly a brake defect with my car as i dont see how an EV on one pedal driving has needed to have front rotors resurfaced 2x and replaced 1x, needed new front pads, and need rear pads resurfaced 1x in less then 2 years/28K miles. Summary of brake repairs - 18k Miles - front rotors re-surfaced - 22k miles - front rotors replaced - 28k miles - front and rear rotors re-surfaced / front pads replaced INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I just had a similar experience about four hours ago during normal conditions (dry and daylight). I was approaching a red light that controlled an on/off ramp intersection where a rural road intersects a state Highway. I was on the rural road. As I started braking, the pedal almost immediately felt soft. I kept pressing (never pumped) the brake pedal steadily lexpecting to feel more normal resistance. The brake pedal traveled more than double the distance that it normally does. I started to get some braking, but I don’t think I could have locked up the brakes if I wanted to. The emergency braking didn’t engage; however, there wasn’t a car traveling in my lane between me and the intersection. There were cars exiting the freeway and turning through the intersection immediately in front of me. Fortunately, I had enough brakes to stop just before the intersection. I had my wife and son in the car. I will be having the local Ford dealership look over the car. That incident happened 5-10 minutes after leaving my house. I had used my brakes during this trip prior to the incident. The brakes worked normally for the remainder of the 20 minute trip. Whatever is going on, isn’t right and although I never was dangerously close to an accident, if conditions were slightly different it could have been very bad.

Brakes automatically engage when parked. Next time I went to drive the car wouldn't move until a loud "clunk" came from the rear and the car moved. But, when I started driving there was a repetitive noise coming with each turn of a rear wheel. Parked the car and took to dealership which confirmed that a "chunk" of the brake pad had come off and adhered to the brake rotor. Contacted Ford and was told that it wasn't covered under warranty because I had gone more than 12, 000 miles. They did set up a case (CAS-46526025-Q7S5V2), but I never heard anything from it. In conversation with the dealer, this is apparently a common problem for which Ford has issued at least 2 TSBs (21-2206 & 22-2023) but the term expired before my incident. From reading of other incidents on various forums for the MachE, it is apparent that the problem still persists as in my case and is affecting a number of owners. Ford needs to be pressured into issuing a recall to install improved brake pads/rotors to prevent this problem from occurring. It could happen at a time when it isn't easy to pull over and therefore, cause an accident.