In a significant blow to Ford’s electric vehicle ambitions, the automaker has issued an urgent recall affecting approximately 32,000 Mustang Mach-E vehicles across Canada due to a potentially dangerous door malfunction that could leave passengers trapped inside or doors flying open while driving.
The Transport Canada recall, announced yesterday, affects models manufactured between 2021 and 2024, representing nearly the entire Canadian fleet of the company’s flagship electric crossover. The issue stems from a faulty door latch mechanism that may cause the doors to unlatch unexpectedly during operation or, conversely, fail to open at all—creating serious safety concerns in emergency situations.
“This particular defect presents a troubling scenario where occupants could find themselves unable to exit the vehicle following a collision,” explained automotive safety analyst Martin Chen in an interview with CO24 Business. “Equally concerning is the possibility of doors opening during vehicle operation, which creates obvious hazards for both occupants and surrounding traffic.”
Ford’s internal investigation revealed that the door latch actuator, a critical component controlling the lock mechanism, may experience electronic failures due to software glitches or wiring issues. The company has documented 27 instances of malfunctions in Canadian vehicles, though thankfully none have resulted in reported injuries.
For affected owners, Ford has outlined a clear remediation plan. Dealers will update the door control module software and inspect the physical latch mechanisms, replacing any compromised components at no cost. The repair process is expected to take approximately two hours per vehicle.
This recall represents the latest setback for Ford’s electric vehicle program in Canada, which has faced multiple quality control challenges since the Mach-E’s introduction. Last year, the company recalled nearly 15,000 units over high-voltage battery contactor concerns that could lead to power loss while driving.
Industry experts note the timing could hardly be worse for Ford, as the company faces increasing competition in the electric vehicle market from both established manufacturers and emerging players.
“These recurring quality issues damage consumer confidence at a critical juncture in the EV adoption curve,” said Elaine Thompson, director of electric vehicle market research at CanadaAuto Institute. “When potential buyers are already anxious about new technology, reliability concerns become magnified and can significantly impact purchasing decisions.”
Ford Canada spokesperson Jacqueline Moore emphasized the company’s commitment to resolving the issue expeditiously. “The safety of our customers remains our highest priority,” Moore stated. “We’re implementing a comprehensive solution and working closely with Transport Canada to ensure all affected vehicles receive prompt attention.”
Affected owners will receive direct notification by mail starting next week, but concerned drivers can check their vehicle’s status immediately by entering their Vehicle Identification Number on Ford’s dedicated recall website or by contacting their local dealership.
As the automotive industry continues its electric transformation, this incident raises important questions about quality control in the rapidly evolving EV marketplace: Are manufacturers sacrificing reliability in their race to bring new electric models to market, and what responsibility do they bear to ensure these technological leaps don’t come at the expense of basic safety?
