Ford Recalls Nearly 200,000 Electric Mustangs Over Serious Door Lock Flaw

Ford is facing yet another major recall, this time involving its flagship electric vehicle, the Mustang Mach-E. Nearly 200,000 units in the U.S. — and over 120,000 more internationally — are being recalled due to a defect that could cause the doors to remain locked unexpectedly. The issue, linked to the vehicle’s software, has raised serious safety concerns, especially after reports surfaced of children being trapped inside.

Locking People In — or Out

The National Highway Traffic Safety Administration (NHTSA) published documents confirming the issue occurs in specific conditions — primarily when the vehicle’s 12-volt battery is low. If the driver or front passenger exits the car and shuts the door under these conditions, the electronic latches may remain locked, rendering the doors unusable from either the inside or the outside.

This glitch presents a major hazard. If a child or pet is inside, they may be unable to escape, particularly if they’re too young or small to reach or operate manual emergency releases. Moreover, some users report that even jump-starting the low battery fails to unlock the doors, further compounding the urgency of the issue.

One especially alarming case was shared on the Mustang Mach-E Forum, where a parent described their infant being locked inside the car for over 40 minutes before help arrived. It’s exactly the sort of nightmare scenario that underscores how even high-tech EVs can have very real, very analog consequences.

Ford’s Ongoing Quality Control Struggles

This recall is just the latest in a string of quality control issues for Ford. Alongside Stellantis and Tesla, Ford topped the list for vehicle recalls in 2024. With this year barely half over, Ford has already recalled over a million vehicles in a single campaign earlier in 2025 — and now it’s adding nearly 200,000 more to that tally with the Mach-E issue.

Ford’s recurring recall issues, particularly among its EV lineup, have dented the company’s reputation at a time when it’s pushing hard into electrification. The Mach-E was positioned as a bold, modern reboot of the iconic Mustang name, aiming to compete with Tesla’s Model Y and other electric SUVs. But persistent problems like this door-lock flaw suggest that Ford is still struggling to balance cutting-edge technology with consistent reliability.

What’s Causing the Lockout?

According to the NHTSA filing, the root of the problem lies in software — specifically in how the powertrain control module and the secondary onboard diagnostic module manage electronic door latching in the event of low voltage. Unlike traditional mechanical door systems, the Mach-E relies heavily on electronic controls for entry and exit. That makes it vulnerable to battery-related malfunctions in a way that older vehicles simply aren’t.

And while it’s somewhat understandable that Ford’s engineers might not simulate all scenarios involving a weakened 12-volt battery during testing, many are asking why such a fundamental safety check — whether the doors can be opened in all conditions — was not thoroughly vetted before mass production.

No Physical Repairs Needed, But Not a Fast Fix

The good news for owners is that this recall won’t require a physical part replacement or a visit to the dealership. The solution lies in a software update, which Ford plans to deploy free of charge. All 2021–2025 Mach-E vehicles included in the recall will receive updates to the relevant control modules.

However, here’s the catch: even though Ford will begin mailing out recall notification letters on June 23, the company doesn’t expect to have the actual fix ready until September 29. That’s a long wait — especially for drivers who may be anxious about the potential for getting locked out of their vehicle or, worse, having a child locked in.

Until the update is ready, Ford has issued a stop-sale order, meaning that dealerships are barred from selling affected Mach-E units still on the lot. That’s a clear indicator of the severity of the issue and a necessary step to prevent further risk.

What Owners Should Do Now

If you own a 2021–2025 Mustang Mach-E, you should first check with Ford or your local dealership to confirm if your vehicle is affected. You can also look up your vehicle identification number (VIN) on the NHTSA website.

While waiting for the fix, Ford has not offered a temporary workaround, which is especially frustrating for owners who rely on the vehicle daily. Owners are advised to monitor their 12V battery health and avoid leaving children or pets unattended in the car under any circumstances — even for a short time.

It’s also a good idea to have an emergency plan in place, especially if you have kids. Consider keeping a manual lockout tool handy (though using one may risk damaging the EV’s frameless windows or body). Some owners have also reported success with manually unlocking the car through the FordPass app — though this is not guaranteed in all battery scenarios.

A Recurring Theme for Ford

The recall once again highlights the growing pains facing traditional automakers like Ford as they pivot toward high-tech, software-heavy electric vehicles. Unlike their mechanical predecessors, today’s EVs are increasingly defined by software architecture — which, while flexible and updatable, introduces new categories of risk.

Ford has pledged to improve its quality control processes. CEO Jim Farley admitted in 2023 that Ford had “left billions on the table” due to warranty costs and recall expenses, many of them stemming from software bugs and rushed development timelines. The automaker is now investing in pre-production testing and software validation tools — but turning that ship around takes time.

This Mustang Mach-E recall is a reminder that even small oversights in EV software logic can result in major, very human consequences. And while software can be patched, the damage to consumer trust is harder to repair.

The Bigger Picture

As electric vehicles become more common on U.S. roads, regulators and consumers alike are going to demand higher reliability — not just in battery range or charging speed, but in fundamental aspects of safety and usability.

Ford’s Mach-E has been a success in terms of sales and critical reception, but this kind of recall puts a dent in that momentum. For an automaker hoping to lead in the EV race, that’s a signal to slow down, test thoroughly, and put safety first.

And as for doors? Well, there’s really only one thing they have to do — open when you need them to. Until Ford ensures they always will, the Mach-E’s sleek design and EV credentials won’t count for much in a real emergency.

Bottom Line: Ford’s recall of nearly 200,000 Mustang Mach-Es is a software issue with real safety implications. Owners should stay alert, avoid risky scenarios with the car’s doors, and await the September fix. In the meantime, Ford’s recall woes continue to be a cautionary tale in the EV transition.