A new Mach-E battery pack costs between $24,000 and over $35,000 before labour. However, Ford provides an excellent 8-year/100,000-mile warranty, so you will likely never pay this full cost yourself. This guide will help you understand the true cost, the warranty protection, and how to keep your battery healthy for the car’s entire life.
Mach-E Battery Replacement Cost in 2025
Battery prices change as technology advances and production scales, but currently, the Mach-E battery replacement cost remains high.
Breaking Down the Price by Battery Size
The Mustang Mach-E is available with two primary battery sizes, and replacement costs vary considerably between them:
- Standard Range (SR) Battery: About 70 kWh of usable capacity, costing approximately $24,000 to $28,000 for the battery pack.
- Extended Range (ER) Battery: A Larger pack with about 91 kWh usable capacity, costing around $30,000 to $35,000 or more.
These prices cover the complete battery unit, which includes the battery cells, cooling system, and the Battery Management System (BMS).
Hidden Costs: Labour and Core Charges
- Labour: Replacing an EV battery is complex, requiring special tools and certified technicians. Labour typically adds $1,500 to $4,000, depending on dealer rates and job complexity.
- Core Charge: A refundable deposit charged to ensure the old battery is returned for recycling. This can be several thousand dollars, but it is refunded upon return.
Most battery issues under warranty are minor, such as faulty modules or sensors, not full pack replacements.
Comparing Mach-E Battery Costs to Other EVs
Battery replacement costs for the Mach-E are comparable to other large EVs on the market:
| Vehicle Model | Battery Size (Usable kWh) | Estimated Replacement Cost (Parts Only) |
|---|---|---|
| Ford Mustang Mach-E (ER) | 91 kWh | $30,000 – $35,000 |
| Tesla Model Y (Long Range) | ~75 kWh | $18,000 – $25,000 |
| Chevrolet Bolt EV | 65 kWh | $15,000 – $20,000 |
| Nissan Leaf (Older Model) | 40 kWh | $8,000 – $12,000 |
Understanding the Ford EV Battery Warranty
- Ford offers an 8-year/100,000-mile warranty for the high-voltage battery, which covers:
- Faulty parts or workmanship.
- Battery capacity dropping below 70% of the original capacity within the warranty period.
This means:
- If the battery fails due to manufacturing defects or workmanship, Ford replaces it at no charge.
- If the battery capacity drops below 70% of its original capacity, Ford repairs or replaces the battery free of cost.
Capacity Loss
Battery degradation happens naturally over time. Ford’s warranty triggers if capacity falls below 70%.
- For the 91 kWh ER battery, this means falling below about 63.7 kWh.
- Real-world data suggests most Mach-E owners retain over 90% capacity after 50,000 miles, making it unlikely to hit the 70% limit within warranty.
Warranty Exclusions
Warranty does not cover:
- Accident or collision damage (covered by your insurance).
- Misuse or abuse, such as incorrect charging equipment.
- Water damage from flooding or extreme conditions.
Why Batteries Fail: Causes for Replacement
Battery replacement is rare and usually due to:
- Major accidents affecting the battery.
- Rare sudden internal failures in cells or modules.
Most battery power loss is gradual and covered by the warranty’s capacity protection.
Role of the Battery Management System (BMS)
The Mach-E BMS is a crucial computer system that:
- Monitors and balances every cell in the battery pack.
- Controls charging speed and cooling to protect battery health.
- Detects early problems in individual cells or modules, often avoiding full pack replacement by allowing targeted repairs.
Protecting Your Investment: Tips to Maximise Battery Life
You have the power to help your battery last a long time. By following a few simple rules, you can make sure your Mach-E battery stays healthy for many years.
Charging Habits
The single best advice for long battery life is to follow the “80/20 Rule.”
Daily Charging: For driving every day, try to keep your battery charged between 20% and 80%. Keeping the battery at a very high charge (above 80%) for a long time puts stress on the cells.
Long Trips: Only charge to 100% right before a long road trip. You should then drive the car right away to bring the charge level down.
Temperature Management
Extreme heat and cold are the enemies of battery health.
Heat: Do not leave your car parked in direct, very hot sun with a high charge (like 100%). The Mach-E’s thermal management system will work to cool the battery, but this uses energy.
Cold: The Mach-E is built to handle cold, but charging in very cold weather can be less effective. The car will automatically use energy to warm the battery to the best temperature before charging.
Software Updates and Dealer Maintenance
Always keep your Mach-E’s software up to date. Ford often releases updates that make the BMS work better and safer. Also, follow Ford’s advice for maintenance, which includes checking the battery cooling system.
The Future of Replacement: Lower Costs and Alternatives
The current replacement cost is high, but the future looks much better for electric car owners.
Remanufactured and Third-Party Battery Options
As the Mach-E gets older, there will be a market for fixed and non-Ford battery packs.
Remanufactured Packs: These are original Ford battery packs that have had bad parts replaced. They are sold for a lower price. They are a reliable and cheaper choice for cars whose warranty time is over.
Third-Party Repair: Independent shops are getting better at fixing battery packs one part at a time, instead of replacing the whole unit. This can save owners thousands of dollars.
The Impact of Falling Battery Cell Prices
The cost of the small lithium-ion battery cells has been dropping for many years. As companies make more cells and as new, cheaper battery chemicals become normal, the cost of a full replacement pack will eventually drop. This is a long-term trend that will help all electric car owners.
Conclusion
Replacing a Ford Mustang Mach-E battery is costly, but most drivers never face this bill thanks to Ford’s strong 8-year/100,000-mile warranty. By using smart charging habits, keeping software updated, and protecting the battery from extreme heat or cold, you can make your Mach-E battery last many years and avoid expensive repairs.
FAQs
How long does the Mach-E battery last?
The Mach-E battery is designed to last the whole life of the car, which is often 15 to 20 years. Ford guarantees that the battery will keep at least 70% of its original power for 8 years or 100,000 miles. Based on data from current owners, most batteries are losing power very slowly.
Is the Mach-E battery covered by a separate warranty?
The Mach-E has a standard car warranty (usually 3 years/36,000 miles) and a separate, much longer warranty for the large battery and electric parts (8 years/100,000 miles).
Can I upgrade my Mach-E battery to a larger size?
Not right now. The battery pack is a key part of the car’s structure. It is made for the Standard Range or Extended Range size only. Ford or other companies do not offer upgrading from an SR to an ER battery because the car would need big changes to its body and computer program.
What is the 12V battery replacement cost?
The Mach-E, like all electric cars, also has a normal 12-volt battery. It runs the car’s accessories and starts the large battery system. This battery is much cheaper and easier to replace. The cost for a new 12V battery is usually between $150 and $300, including the work. This is a normal repair item that may need replacing every 3-5 years.
