Ford halts Mustang Mach-E deliveries over door-latch defect

Ford has temporarily stopped deliveries of its all-electric Mustang Mach-E due to a software-related fault that could result in vehicle doors failing to lock or unlock correctly. The safety issue, linked to the discharge of the 12V battery, affects more than 316,000 units globally across model years 2021 to 2025. A software fix is currently expected in Q3.

According to documentation shared with US dealers, the electronic door-latch malfunction can prevent the front doors from unlocking, even after a mechanical exit from the vehicle. If an occupant exits via the manual interior release and the latch remains in its previous state, the door may stay locked when shut—posing a serious safety risk if people or animals are left inside. Ford says it has not received reports of any injuries or accidents tied to the defect.

Until a fix is available, Ford has issued a stop-sale and stop-delivery order for affected units, instructing retailers not to hand over vehicles to customers or offer test drives. The recall impacts roughly 196,900 vehicles in the United States and a further 120,000 units internationally.

Ford is working on a software update to resolve the issue. Nevertheless, early feedback from Mach-E owners suggests the fix may not be deliverable via an over-the-air (OTA) update and could require a visit to the dealer. Once ready, affected customers will be contacted by post and invited to schedule a repair appointment. The software update will be provided free of charge.

The recall comes at a time when Ford is attempting to reduce warranty and quality-related costs—areas in which the company continues to trail competitors such as General Motors. Nonetheless, Mustang Mach-E sales in the US remain steady. In May 2025, Ford delivered 4,724 units—an 11 per cent year-on-year increase. Year-to-date, the model has recorded 19,258 deliveries, up 2.8 per cent compared to the same period in 2024.

The Mach-E has benefitted from several incentive schemes, including the ‘From America, For America’ employee pricing offer and the ‘Ford Power Promise,‘ which covers the cost of a Level 2 home charger and its standard installation. At the same time, the company has introduced mid-year price increases for Mach-E units built in Mexico and shipped after May, citing routine adjustments and additional tariffs.

Ford’s US stock of the Mustang Mach-E stood at 13,400 units at the beginning of June, with an 82-day supply—highlighting the importance of resolving the recall swiftly to avoid a bottleneck in EV distribution during a highly competitive market phase.

electrek.co, detroitnews.com