Volvo Plug-In Hybrid Vehicles Battery Fire Risk

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A critical safety issue has been identified in certain Volvo cars, prompting thousands of owners to bring their vehicles in for repairs. The affected models include the 2020-2021 S90, 2020-2022 S60, V60, XC60, XC90, and 2022 V90 plug-in hybrid vehicles. According to Volvo Cars, a production deviation in the battery module can cause a short circuit when the vehicle is fully charged and parked, increasing the risk of a fire.

The problem arises from a supplier process defect that can lead to an internal short circuit within certain battery cells. This can result in overheating of the battery cells, potentially causing a thermal event when the vehicle is parked and fully charged. Fortunately, Volvo Cars has not received any reports of incidents occurring while driving, and there have been no reported injuries, fatalities, or crashes related to this condition.

The investigation into the issue began in February 2024, after Volvo Cars received its first report of a thermal event. The company’s Critical Concern Action Process (CCAP) was initiated, and a technical investigation was conducted to determine the root cause of the problem. After completing the investigation in March 2025, the Critical Concern Management Team (CCMT) decided to prepare for a recall due to the increased risk to motor vehicle safety.

To address the issue, Volvo Cars is advising owners of affected vehicles not to charge their cars until the remedy has been completed. Dealers will inspect and replace the high-voltage battery module as necessary, and update the software to monitor the battery. Owner notification letters are expected to be mailed on May 15, 2025.

The recall affects a range of Volvo models, including:

  • 2020-2021 S90
  • 2020-2022 S60
  • 2020-2022 V60
  • 2022 V90
  • 2020-2022 XC60
  • 2020-2022 XC90

Volvo Car’s number for this recall is R10312, and the NHTSA campaign number is 25V-179. Owners who receive recall notices are encouraged to contact their local dealerships to schedule the necessary repairs.

Note: Owners are advised to take precautions to minimize the risk of a thermal event. By not charging their vehicles until the remedy has been completed, owners can help prevent any potential fires.

Braking Safety Concern In 2025 Nissan And Infiniti Vehicles

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Nissan has issued a recall for certain 2025 model year Murano, Pathfinder, and Infiniti QX60 vehicles due to a potential braking safety issue. The problem affects the front brake caliper assemblies, which may have reduced strength and could break, leading to reduced braking performance.

The issue was discovered in January 2025 during a routine production brake test on a 2025 Nissan Pathfinder. A technician reported a failure of the front right-hand brake caliper assembly, prompting Nissan to quarantine the defective part and launch an investigation. Further analysis revealed that the suspect brake caliper had been produced with a common supplier production lot code (51A), which was found to have an inadvertent modification to an internal parameter setting. This modification reduced the material’s strength, making it more prone to failure.

The supplier’s investigation confirmed that a total of 3,115 caliper castings were produced in the affected lot and shipped to Nissan for assembly into vehicles. Through traceability records, Nissan identified 2,341 vehicles that may have received a potentially affected brake caliper. Of these vehicles, 711 were held for inspection, while 200 had been exported and 1,430 had previously been shipped to the US.

According to Nissan, if one or both of the front brake calipers fail, it can result in reduced braking performance and may not comply with certain performance requirements of Federal Motor Vehicle Safety Standard (FMVSS) 135. This could increase the risk of a crash, particularly if drivers are unable to stop their vehicles in time. Affected customers may notice uneven braking performance, and the “Low Brake Fluid” warning light may illuminate in certain cases.

To address the issue, Nissan will be recalling affected vehicles and asking owners to return to their dealerships for an inspection and replacement of the front brake caliper assemblies as necessary. Owner notification letters are expected to be mailed on May 9, 2025. The recall is identified as Nissan’s numbers PD137 and PD138, and the NHTSA campaign number is 25V-173. This issue highlights the importance of rigorous testing and quality control measures in ensuring the safety of vehicles on the road.

Ford and Lincoln Transmission Valve Failure

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A critical issue affecting the transmission valve body of certain Ford Bronco, Explorer, F-150, Mustang, Ranger, and Lincoln Aviator vehicles can cause reverse gear failure or unexpected forward movement while in reverse or neutral gear. This problem could be a significant safety risk to drivers and passengers.

According to Ford, the issue is attributed to an incorrectly machined transmission valve body, specifically the Outer Valve Body (OVB) of the transmission main control. The machining tool used during production did not maintain proper specifications, resulting in out-of-specification dimensions that can prevent the vehicle from entering reverse gear when commanded by the gear shift module.

Symptoms of the problem include no reverse motion when the gear selector is in reverse, and in some cases, the vehicle may move forward with the gear selector in either reverse or neutral position. The Malfunction Indicator Light (MIL) and Wrench light will illuminate on the dashboard when this malfunction occurs.

The recall affects vehicles, including:

  • 2024-2025 Ford Bronco
  • 2025 Ford Explorer
  • 2024-2025 Ford F-150
  • 2025 Ford Mustang
  • 2024 Ford Ranger
  • 2025 Lincoln Aviator

Ford’s investigation into the matter began in February 2025, after a transmission failure was reported on a 2025 Mustang at the Flat Rock Assembly Plant. The company subsequently issued a Stop Ship order for affected models and launched an analysis of the suspect transmissions.

Using advanced data analytics, including Machine Integrated Learning and Optimization (MILO) modeling, Ford identified individual Outer Valve Body units that were likely to experience this condition. The company then conducted evaluations of vehicles equipped with suspect parts and confirmed the symptoms reported by customers.

As of February 21, 2025, Ford had received five warranty reports related to this issue. On March 7, 2025, the company’s Field Review Committee approved a field action, which includes replacing the transmission main control valve body.

Ford has notified owners of affected vehicles and has begun repairing the transmissions. The recall is identified as Ford’s number 25S19 and NHTSA Campaign Number 25V-164.

This recall highlights the importance of rigorous quality control measures in the automotive manufacturing process. The issue serves as a reminder that even minor defects can have significant consequences on vehicle safety and performance.

Starter Generator Connection May Fail In BMW Vehicles

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Certain 2025 BMW models may have a battery connection problem that affects the electrical connection between the starter-generator and battery. This connection may come loose over time, leading to serious consequences.

The affected vehicles include the 2025 BMW 330i, 330i xDrive, 430i, 430i xDrive, 530i, 530i xDrive, and X3. The problem was discovered in December 2024, when a dealer field report from a non-US market mentioned a no-start condition and a burning odor within the engine compartment. An inspection found indications of local smoldering at the connection between the positive battery cable and the starter-generator.

After conducting an engineering investigation and reviewing additional incidents, BMW determined that the issue was related to the power connector component of the starter generator, which may not have been produced according to specifications. A gap could form at the connector location during production, causing a loose connection between the connector and the positive battery cable. This can lead to resistive heating, resulting in a loss of charging function and engine stalling without warning. In extreme cases, overheating could increase the risk of smoldering and even fire. Fortunately, BMW has not received any reports of accidents or injuries related to this issue.

Battery Problem

To address the problem, owners of affected vehicles will be asked to return to their dealers for an inspection and replacement of the starter-generator and positive battery cable as necessary. Owner notification letters are expected to be mailed on May 23, 2025. The recall is identified by NHTSA campaign number 25V-202.

This afety recall aims to prevent any potential risks associated with this issue. Owners of affected vehicles should take immediate action to schedule an appointment with their dealer to have the necessary repairs made. By doing so, they can ensure their vehicle remains safe and reliable on the road.

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2025 Chrysler Pacifica PHEVs – Insufficient Bolt Torque on Front Brake Caliper Bracket

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A potential safety issue has been identified in some 2025 Chrysler Pacifica Plug-In Hybrid Electric Vehicles (PHEVs) that may have been produced with insufficient bolt torque on the front brake caliper bracket. The problem, which affects vehicles produced on December 19, 2024, can lead to a range of serious consequences, including reduced steering control, brake fluid leakage, and diminished front braking performance.

According to FCA US LLC (FCA US), the issue was first identified on February 20, 2025, when the Technical Safety and Regulatory Compliance (TSRC) organization opened an investigation into the matter. The company worked with its engineering team and supplier to understand the potential consequences of the problem and determine if any vehicles with suspect front brake caliper brackets had left the factory.

As of March 13, 2025, FCA US is aware of one warranty claim related to this issue, which was received on January 8, 2025. However, there have been no field reports of accidents or injuries resulting from the problem.

The suspect vehicles were produced with front brake caliper bracket bolts that were not properly torqued, which can cause the bracket to separate from the steering knuckle. This can lead to a range of serious safety issues, including reduced steering control and diminished braking performance. In certain crashes, this can increase the risk of injury to occupants of the vehicle.

To address the issue, FCA US will be conducting a recall of affected vehicles. Dealers will inspect and replace the front brake caliper brackets and bolts as necessary, free of charge. Owner notification letters are expected to be mailed on April 24, 2025. The recall is identified as FCA’s number 27C and the NHTSA campaign number is 25V-191.

Vehicle owners who receive a notification letter should contact their local Chrysler dealer to schedule an appointment for the inspection and repair. It is essential to have the issue addressed promptly to ensure the safety of the vehicle’s occupants and other road users. The recall highlights the importance of regular maintenance and inspections to identify potential safety issues before they become major problems. FCA US’s prompt action in addressing the issue demonstrates its commitment to ensuring the safety and quality of its vehicles.

If you own a 2025 Chrysler Pacifica PHEV, it is essential to be aware of this potential issue and take immediate action if you receive a notification letter. By doing so, you can help ensure your safety and the safety of others on the road.

2020-2022 Ford Explorer Repeated Repair Attempts

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Ford Explorer Axle Problem
Certain 2020-2022 Ford Explorer Vehicles May Still Be at Risk

A critical issue affecting certain 2020-2022 Ford Explorer vehicles has come to light, despite previous repair attempts under recalls 23V-199 or 22V-255. The problem lies in the rear axle horizontal mounting bolt, which may fracture and cause the driveshaft to disconnect. This can lead to a loss of forward power, increased risk of crash and injury, and even unintended vehicle movement.

The root cause of the issue is attributed to a software tool malfunction that failed to upload the correct software update to the vehicle during previous repair attempts. As a result, the underlying condition specified in Safety Recalls 23S16 / 23V-675 and 22S27 / 22V-255 may still exist, putting drivers and passengers at risk.

The Technical Explanation

Affected vehicles were built with a 3-point mounted axle design, which can lead to a fracture of the rear axle horizontal mounting bolt. When powertrain torque is applied through the driveline, it causes axle rotation, exerting a bending force on the rear axle bolt. Repeated peak torque events, typically experienced during launch events, can cause fatigue failure of the bolt. This can result in a loud, grinding, binding, or clunking noise, as well as severe vibration.

The Consequences

If the rear axle bolt breaks, the driveshaft or half-shafts may become disconnected, leading to a loss of forward power and transmission torque to the rear wheels. This increases the risk of crash and injury. Furthermore, if the parking brake is not applied, the loss of primary park torque can allow the vehicle to roll in park, increasing the risk of crash and injury.

The Solution

To correct the problem, dealers will update the powertrain control module (PCM) software. Ford’s number for this recall is 25S22, and the NHTSA campaign number is 25V-166. It is essential that owners of affected vehicles take immediate action to have their vehicle repaired to prevent any potential accidents or injuries.

Certain 2022-2024 Ford F-150 Lightning BEVs May Have A Battery Defect

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A potential safety issue has been identified in a small number of 2022-2024 Ford F-150 Lightning Battery Electric Vehicles (BEVs). The problem affects the high voltage battery cells, which may have a manufacturing defect that can cause an internal short circuit. This defect is due to misaligned electrodes in the battery cells, which can occur over repeated charge and discharge cycles.

The issue was first brought to Ford’s attention in October 2024, when a fire was reported in a 2022 model year F-150 BEV. Further investigation revealed two additional fires in 2022 and 2023 model year vehicles, prompting Ford to launch a broader inquiry into the matter. Although no physical samples were initially available for analysis, Ford’s Field Review Committee authorized a program to collect and evaluate additional samples from the field.

The subsequent tear-down analysis of the returned battery arrays revealed evidence of misaligned electrodes in the high voltage battery cells. The supplier also found that eight stacker machines between two production lines had produced cells with cathode shift, which did not meet the design requirements. This manufacturing concern resulted in overlap that fell short of the required standards. Notably, some of the cells from vehicles that experienced fires were manufactured during this time frame.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire and decided to approve a safety recall. The recall affects certain 2022-2024 Ford F-150 Lightning BEVs, and owners are advised to take precautions until the repair is completed. Specifically, owners should only charge their vehicles to a maximum of 80% battery capacity to minimize the risk of an internal short circuit.

To address this issue, dealers will inspect and replace the high voltage battery array as necessary. Owner notification letters are expected to be mailed on March 17, 2025. Ford’s recall number for this issue is 25S18, and the National Highway Traffic Safety Administration (NHTSA) has assigned a campaign number of 25V-131.

Ford Fusion Energi Problems: Understand the Risks and Your Options

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The 2019-2020 Ford Fusion Energi has been plagued by a series of problems, including a critical safety recall that has left many owners concerned about their vehicle’s reliability and safety. This article talks about the issues affecting these vehicles, including recall 23S33, and provide you with essential information to help you navigate this situation.

Recall 23S33: A Fire Risk in the Trunk Area

In recent months, Ford has issued a voluntary recall (23S33) for certain 2019-2020 Ford Fusion Energi models due to a potential fire risk in the trunk area. According to the defect report, the high-voltage battery in these vehicles can overheat, causing a fire that may spread to other parts of the vehicle. This defect can occur when the vehicle is being driven or parked. It’s not uncommon for owners to experience symptoms such as:

  • A burning smell while driving
  • The vehicle displaying a “Stop Safely Now” message
  • A loss of power within seconds
  • A fire breaking out in the trunk area

Other Problems Affecting the Ford Fusion Energi

In addition to the recall, many owners have reported other issues with their 2019-2020 Ford Fusion Energi vehicles. Some common problems include:

  • Transmission Issues: Owners have complained about rough shifting, hesitation, and failure to engage gears properly.
  • Electrical System Malfunctions: Faulty wiring, faulty sensors, and software glitches have caused a range of issues, including erratic behavior from the vehicle’s systems.
  • Battery Drain: Some owners have experienced premature battery drain, which can leave them stranded.

Lemon Laws and Your Rights

If your 2019-2020 Ford Fusion Energi has been plagued by repeated problems, you may be entitled to relief under state or federal lemon laws. These laws are designed to protect consumers from defective vehicles and provide a range of remedies, including refunds, replacements, and compensation for damages.

Conclusion

The 2019-2020 Ford Fusion Energi recall is a serious issue that affects not only the vehicle’s safety but also its overall reliability. If you’re an owner of one of these vehicles, it’s crucial to stay informed about the latest developments and take proactive steps to protect yourself and your passengers. By understanding your options and rights under lemon laws, you can navigate this situation with confidence and ensure that your voice is heard.