Ford Mustang Mach-E: Common Issues and Repair Costs
The Ford Mustang Mach-E is one of the most popular electric SUVs on the road. While it’s earned praise for performance and design, owners have also reported specific issues over time. Below is a clear breakdown of common problems, real-world repair costs and what you should watch for in 2025.
1. Door Latch Recall Problem (2021–2025 Models)
Issue: A software bug in the control system can cause the rear doors to stay locked if the 12-volt battery drops below around 8.4 volts. This means the rear doors might not open from the inside, raising safety concerns for anyone in the back.
Fix: Ford issued a recall for nearly 200,000 vehicles. A free software update will fix the issue by September 2025. In the meantime, Ford dealers have paused sales until updates are done.
Cost to fix: Free at dealership (covered by recall)
2. Battery and Charging System Faults
Some owners have reported the following:
- 12V battery dying prematurely
- Battery fault warnings on the dash
- Car not charging properly or randomly stopping mid-charge
Cause: Often linked to early software bugs or faulty battery control modules.
Fix: Ford has released multiple software updates. In some cases, components like the charge port controller or the battery junction box need replacement.
Repair cost if not under warranty:
- Battery junction box: £850–£1,200
- Charge controller unit: £300–£500
- Labour: £100–£200
3. Software and Infotainment Glitches
Problems reported:
- CarPlay audio randomly cuts out
- Reverse camera freezes
- Central screen goes black while driving
- Lag in response to touch commands
Fix: Most software bugs are resolved by performing a reset or installing the latest Ford Power-Up over-the-air update.
Cost:
- In warranty: Free
- Out of warranty: Software reset or module replacement £150–£400
4. Mechanical Issues (Rare but Reported)
While most Mach-E owners report smooth driving, there have been some less common mechanical issues:
- Rear drive unit noise or failure
- Parking brake stuck
- Front wheel bearings wearing early
- Rear suspension creaking or knocking
Repairs:
- Rear drive unit replacement: £2,000–£3,500
- Wheel bearing replacement: £350–£500
- Suspension arm or bushings: £250–£600
- Parking brake service or motor: £300–£450
5. Water Leaks and Boot Seal Failures
Some owners report:
- Water getting into the boot after heavy rain
- Condensation in the tail lights
Cause: Weak weather seals around the boot lid or poor drainage in the light housing.
Repair cost:
- Boot seal replacement: £150–£250
- Tail light housing fix: £200–£400
6. Average Repair and Maintenance Costs
Here’s a simple breakdown of common services and costs:
| Service / Repair | Typical UK Cost |
|---|---|
| 10,000-mile service (basic) | £80–£120 |
| Cabin filter change | £30–£60 |
| Brake inspection | £100–£150 |
| Coolant system service | £180–£300 |
| Headlamp control module | £600–£750 |
| Infotainment screen replacement | £700–£1,000 |
| Side mirror replacement | £1,100–£1,300 |
| Battery control module | £800–£1,200 |
Long-Term Cost Estimate (10-Year Ownership)
- Total maintenance and repair cost: £4,500–£5,500
- Chance of major repair by year 10: ~27%
- First 5 years typical cost: ~£1,500–£2,000 (if out of warranty)
Owner Tips to Reduce Problems
- Always install the latest Ford software updates – they solve most issues
- Get regular dealer check-ups, even if minor
- Avoid letting the 12V battery discharge fully
- Wash the boot seals and inspect for leaks regularly
- If buying used, check recall work has been done
Final Thoughts
The Ford Mustang Mach-E offers strong performance and lower running costs than petrol SUVs. But like any new-gen EV, early software issues and rare mechanical faults do appear. As long as you stay on top of recalls and updates, the Mach-E is still one of the most reliable electric SUVs in its class for 2025.
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