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Investigation into Fire Hazards of Enel X Way USA’s JuiceBox Level 2 Residential EV Chargers

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Enel X Way USA’s JuiceBox Level 2 residential EV chargersThe National Highway Traffic Safety Administration (NHTSA) has launched an investigation into potential fire hazards associated with Enel X Way USA’s JuiceBox Level 2 residential EV chargers. Prompted by several complaints received by the Office of Defects Investigation (ODI), this evaluation aims to determine the extent and safety implications of electrical arcing and thermal incidents reported by users of these chargers. This probe focuses on the potential for fire risks arising from electrical malfunctions and the company’s recent operational shutdown announcement.

Summary of Complaints Filed with ODI

ODI has received six Vehicle Owner Questionnaires (VOQs) concerning alleged incidents involving the JuiceBox Level 2 charger. These complaints raise serious concerns regarding potential fire hazards that may arise while charging electric vehicles at home. The following highlights from the complaints showcase the range of issues reported:

  1. Total Home Loss Due to Explosion: One complaint involves a significant incident where a vehicle owner claims that charging their EV with a JuiceBox led to an explosion in their garage. This catastrophic event resulted in a fire that destroyed the home entirely.
  2. Car Fire in Driveway: Another complaint describes an incident where a vehicle caught fire in the driveway while connected to a JuiceBox charger. The details of this incident underscore concerns about charger reliability and the potential for dangerous outcomes.
  3. Electrical Malfunctions and Circuit Breaker Issues: Four additional complaints describe issues with electrical malfunctions that caused circuit breakers to trip and charging cycles to be disrupted. These electrical disruptions may indicate underlying issues with the chargers’ compatibility or durability under varying conditions.

Enel X Way’s Operational Shutdown and Potential Impact on User Safety

In an unexpected development, Enel X Way North America announced its intention to cease operations in the United States and Canada by October 11, 2024. A notification was sent to JuiceBox owners on October 2, 2024, which was also posted on the company’s website. This cessation of operations could potentially impact several aspects of the product’s performance and user experience:

  • Software and App Support: As Enel X Way discontinues its North American presence, questions remain about the continuity of the charging app and supporting software. Given that many smart chargers rely on connected software for updates and safety monitoring, the lack of support could leave users with outdated or unsupported technology.
  • Customer Support and Warranty Services: The cessation of operations may also impact the company’s ability to provide customer support, particularly regarding ongoing technical issues, troubleshooting, or warranty claims for JuiceBox chargers.

ODI Preliminary Evaluation and Safety Scope

In response to these serious complaints, ODI has opened a Preliminary Evaluation to examine the safety and reliability of JuiceBox Level 2 chargers. The purpose of this evaluation is to assess the scope, frequency, and potential hazards associated with these products. The investigation seeks to determine:

  • Risk of Fire and Explosion: By evaluating complaints of thermal events, such as the explosion in the garage and the driveway car fire, ODI aims to understand the risk factors and whether the JuiceBox charger’s design or operational faults are contributing factors.
  • Electrical Stability and Safety Consequences: ODI’s analysis will also delve into the frequency of electrical malfunctions and whether these events pose a risk of property damage, personal injury, or loss of life.
  • Impact of Software and Operational Changes: With the discontinuation of Enel X Way North America’s operations, ODI is concerned about the potential safety implications arising from the lack of app and software support. The investigation will evaluate if and how this operational change might exacerbate existing safety concerns or introduce new risks.

Affected Vehicles and Part Numbers

The ODI investigation includes a review of incidents involving various EV models that utilized the JuiceBox Level 2 charger. The vehicles associated with these complaints include:

  • Chevrolet Bolt EV (2018)
  • Chrysler Pacifica Hybrid (2018)
  • Hyundai Ioniq 5 (2022)
  • Hyundai Ioniq 6 (2023)

Additionally, the specific product part under scrutiny is the Enel X JuiceBox Level 2 Charger.

Steps for Consumers and Further Information

For EV owners who currently use the JuiceBox Level 2 charger, awareness of this investigation is crucial. Users are encouraged to follow any guidance issued by the NHTSA and consider consulting with licensed electricians to ensure proper installation and safe operation of their EV chargers.

GM Roof Rail Air Bag Inflator Defect

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General Motors (GM) have identified a safety issue affecting certain Chevrolet and GMC vehicles. This issue involves a defect in the roof-rail airbag (RRAB) inflator, which could pose a serious risk to the safety of drivers and passengers. The defect may cause the inflator to malfunction, potentially resulting in the separation of the inflator’s end cap or a split in its sidewall. If this happens, the airbag system may not deploy as intended, increasing the risk of injury in the event of a crash or other incident.

Affected Vehicle Models

The following models are impacted by this recall due to the potential defect in the RRAB inflators:
2018 Chevrolet Silverado 1500
2018-2019 Chevrolet Silverado 2500
2018-2019 Chevrolet Silverado 3500
2018 GMC Sierra 1500
2018-2019 GMC Sierra 2500
2018-2019 GMC Sierra 3500

How the Issue Was Discovered

GM became aware of this problem in August 2024, after receiving reports of four incidents where RRAB inflators ruptured in vehicles from another manufacturer. These reports raised concerns about a possible defect in the inflator system, prompting GM to initiate its own investigation. During this investigation, GM found evidence of a similar incident involving a 2018 Chevrolet Silverado 2500, which was equipped with the same type of inflators.

In this particular case, the vehicle was parked and unoccupied when the RRAB inflator on the right side ruptured. Photos confirmed the inflator malfunctioned while the truck was idle, reinforcing concerns about the integrity of the RRAB system. GM is continuing its investigation to determine the exact cause of the failure.

Steps Taken by GM

On October 3, 2024, GM’s Safety Field Action Decision Authority (SFADA) determined that a safety recall was necessary. This recall affects vehicles that were built using RRAB inflators from the same production lot as the Chevrolet Silverado 2500 involved in the initial incident. As of now, GM has not received any further reports of similar incidents involving its vehicles.

What Owners Need to Know

To address this issue, GM dealers will replace the left and right roof-rail airbag modules in the affected vehicles. This recall is part of GM’s proactive efforts to ensure vehicle safety and prevent potential accidents resulting from defective inflators.

For reference, GM has assigned this recall the number N242474500, and the National Highway Traffic Safety Administration (NHTSA) has labeled it as campaign number 24V-560.

2021 Nissan Rogue Safety Investigations: Tie Rod Failures and Engine Issues

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The 2021 Nissan Rogue, one of Nissan’s popular compact SUVs, is currently under investigation by the Office of Defects Investigation (ODI) due to reports of safety defects. Two major concerns have emerged—one involving inner tie rod failures that could lead to a loss of steering control, and the other concerning engine failures that could result in a complete loss of motive power. These issues raise significant safety risks for drivers and passengers, and Nissan is facing increasing scrutiny as the investigations unfold.

Inner Tie Rod Failures: Loss of Steering Control

Nissan Rogue Tie Rod FailureOne of the top issues reported is inner tie rod failures, which can lead to a sudden and complete loss of steering control. The ODI received reports from owners and early warning data indicating that these failures can occur on either the driver’s or passenger’s side of the vehicle. In several instances, the vehicles had to be towed for repairs.

One notable case involved a 2021 Nissan Rogue owner who experienced a sudden and severe steering malfunction while pulling out of a parking lot. According to the owner, the steering wheel suddenly pulled to the right, causing the front passenger tire to become misaligned. The vehicle became undrivable, multiple warning lights illuminated, and it had to be towed to a dealership. Although the dealership diagnosed a bent tie rod and performed a repair, the steering wheel did not return to its normal position. The owner reported no impact that could have caused the damage, yet the manufacturer declined to cover the repair under warranty. This incident occurred with just over 16,600 miles on the vehicle, raising concerns about the durability and safety of the Rogue’s steering system.

This ongoing investigation into tie rod failures has raised serious concerns about the overall safety of the vehicle, as a sudden loss of steering control could lead to catastrophic accidents.

Engine Failures: Loss of Motive Power

In addition to the tie rod issue, the 2021 Nissan Rogue is also under investigation for engine failures that could lead to a complete loss of motive power. The ODI has identified multiple reports of engine knock, strange noises, and metal chunks or shavings found in the oil pan of vehicles equipped with Nissan’s KR15DDT and KR20DDET engines. The KR15DDT, a 1.5-liter 3-cylinder engine, is found in the Rogue, while the KR20DDET, a 2.0-liter 4-cylinder engine, powers other models such as the Altima, QX50, and QX55.

The variable compression ratio engines, designed to deliver both high power and fuel efficiency, have shown an elevated failure rate. These engine issues have been linked to bearing and L-link damage, which could lead to total engine failure, leaving drivers stranded or worse, in a dangerous situation while driving. Nissan has made manufacturing changes in an attempt to address these issues, but the investigation is still open as the company works to find a more permanent solution.

Alongside these investigations, the 2021 Nissan Rogue has been the subject of several recalls, addressing a variety of safety concerns:

  1. Missing Internal Bushing in Brake Calipers – This defect could lead to brake fluid loss, reducing braking performance and increasing the risk of a crash.
  2. Rear View Camera Malfunctions – The rearview camera display may become inoperative, reducing rear visibility and raising the risk of an accident.
  3. Seat Belt Retraction Issues – Some seat belts may not retract properly, making them difficult to use, which could increase the risk of injury in a crash.
  4. Fuel Pump Overheating – An overheated fuel pump can cause the engine to stall unexpectedly, posing a serious safety risk.
  5. Second Row Seatback Welding Issues – Improperly welded seatbacks may fail to secure a child seat, increasing the risk of injury in the event of a sudden stop or crash.
  6. Wheel Separation Risk – Incorrectly fitted wheel nuts could cause the wheel assembly to separate from the vehicle, which could result in a loss of vehicle control.
  7. Fuel Hose Detachment – A poorly secured fuel hose can disconnect, causing a fuel leak or engine stall, both of which increase the risk of fire or crash.

With ongoing investigations into tie rod and engine failures, as well as several recalls addressing safety concerns, the 2021 Nissan Rogue has been thrust into the spotlight for potential safety risks. Drivers should stay informed about any updates from Nissan and take immediate action if their vehicle is affected by any recalls or investigations. Safety should always be a top priority, and these investigations aim to ensure that any defects are properly addressed to protect drivers on the road.

Porsche Taycan Potential Battery Fire

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Certain Porsche Taycan models from 2021 to 2024 may face issues with their high-voltage batteries, specifically the potential for short circuits within the battery modules. These short circuits could result in thermal events, including the risk of overheating or even fires in extreme cases. The root cause of this issue has been traced back to potential manufacturing problems from the battery supplier, which, in rare instances, increase the likelihood of internal short circuits.

This latest recall builds on earlier recalls that were issued for similar battery-related problems, namely 23V-840 (manufacturer recall code APB5), 24V-215 (code ARA4), and 24V-217 (code ARA5). Porsche has been using data analytics and conducting hardware tests to better understand the extent of the issue. On September 23, 2024, the company determined that additional Taycan vehicles might be at risk due to potential battery defects, even though no confirmed data anomalies have been identified in these vehicles so far. As a result, Porsche launched a new recall with the identification codes ARB6 and ARB7.

Breakdown of ARB6 and ARB7 Recalls

  • ARB6: This recall covers a group of vehicles for which Porsche does not have enough data to determine whether there are issues with the high-voltage batteries. Since there isn’t sufficient information, Porsche is taking precautionary measures. Owners of vehicles in this group will receive a notification advising them to limit their battery’s charging capacity to a maximum of 80%. This is intended as a temporary solution while further analysis is conducted to either confirm the presence of battery anomalies or clear the vehicle of any issues. This interim step is designed to reduce the risk of thermal events while Porsche continues its investigation.
  • ARB7: In contrast, ARB7 applies to a set of vehicles for which Porsche has gathered sufficient battery data, and current diagnostics show no data anomalies in the high-voltage battery. As a result, there is no need to restrict battery charging for these vehicles to 80%. What sets this group apart is that these vehicles allow Porsche to continuously monitor the battery health via over-the-air updates. This real-time data monitoring enables Porsche to detect any future battery module issues quickly. If an anomaly is detected later, Porsche will notify owners, replace the affected battery module, and advise them to limit charging to 80% until the replacement is completed.

As part of this recall process, Porsche is implementing a series of steps to address the potential battery issues:

  • For ARB6 Vehicles: Owners are advised to cap their battery charging at 80% until a more permanent solution is available. This is purely a precautionary measure while Porsche continues to analyze the vehicles and gather more data on the potential risks.
  • For ARB7 Vehicles: Since Porsche already has access to these vehicles’ battery data via over-the-air diagnostics, there is no need for an 80% charging limit unless future data shows a problem. Porsche’s real-time monitoring will automatically detect any battery module anomalies. Should a problem arise, the company will issue a notification to the owner, and the affected battery modules will be replaced. In the meantime, Porsche will advise affected owners to limit charging to 80% as a safeguard.

For both ARB6 and ARB7, the final remedy will involve installing an advanced on-board diagnostic software on all affected vehicles. This software will be capable of detecting potential battery anomalies before they become serious. However, before this software is installed, Porsche will conduct an analysis of the battery modules in each vehicle. If the analysis shows that no problems are present, the software will be installed immediately. If the analysis detects any issues, Porsche will replace the faulty battery module(s) before proceeding with the installation of the diagnostic software.

Once the new on-board diagnostic software is installed, it will continuously monitor the vehicle’s high-voltage battery using advanced data analytics. If the software detects an anomaly in any of the battery modules, it will send a warning message to the vehicle’s head unit, alerting the driver. In this case, the battery’s charging capacity will be automatically limited in stages: first to 80%, and eventually to a lower limit, likely around 50%, depending on the severity of the detected anomaly. This stepwise reduction in charging capacity helps prevent thermal events and gives the driver time to seek service. If necessary, Porsche will replace the affected battery modules to restore the vehicle’s full functionality. Since the battery consists of multiple modules, it is possible that different modules could show issues at different times, requiring multiple replacements over the vehicle’s lifetime.

Porsche plans to roll out this advanced diagnostic software as the final remedy in the first quarter of 2025. In the meantime, dealers will be prepared to install interim software and address any battery concerns as they arise. Owners of affected vehicles will receive notification letters starting on November 29, 2024. These letters will provide detailed instructions on what steps to take next and how to proceed with repairs or updates.

The recall numbers for this issue are ARB6 and ARB7. Additionally, the National Highway Traffic Safety Administration (NHTSA) has assigned campaign numbers 24V-731 and 24V-732 to these recalls. These recalls build on and replace the earlier recalls 23V-840, 24V-215, and 24V-217, expanding the affected vehicle population as Porsche continues its investigation.

Nissan Leaf Fire Risk From Quick Charging Battery

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Nissan Leaf Smoking BatteryCertain 2019-2020 Nissan Leaf vehicles, specifically those equipped with quick charge ports for Level 3 charging using the CHAdeMO connector, are facing a potential issue where the battery could overheat during quick charging. This issue is serious, as it significantly raises the risk of a vehicle fire, which could lead to injury or property damage. The affected LEAF models were produced at Nissan’s Smyrna, Tennessee plant between August 29, 2018, and November 3, 2020. Nissan has identified this issue through their production records, confirming that it is limited to these specific Model Year 2019-2020 LEAF vehicles. Importantly, no other Nissan or INFINITI vehicles are known to be impacted by this defect, offering some reassurance to owners of other Nissan models.

Nissan is actively investigating the cause of this issue. Preliminary findings suggest that the problem stems from excessive lithium deposits forming inside the lithium-ion battery cells of these vehicles. These deposits increase the electrical resistance within the battery, which can cause fluctuations in the battery’s state of charge. This elevated resistance becomes particularly problematic during Level 3 quick charging, as it may result in the battery heating up more rapidly than intended. If the charging session continues under these conditions, the risk of a battery fire is significantly heightened, posing a serious safety concern.

Drivers may notice several warning signs during Level 3 charging that indicate something is wrong. These include the presence of smoke, unusual noises, interrupted charging sessions, or strange thermal odors emanating from the vehicle’s battery compartment. If any of these signs are observed, Nissan strongly advises stopping the charging process immediately and avoiding Level 3 charging altogether until the problem can be resolved.

Nissan is developing a solution for this issue in the form of a software update for the affected vehicles. Once available, this software update will be installed by dealers and is designed to correct the problem by managing the battery’s charging process more effectively. Nissan is taking steps to notify affected vehicle owners. Interim letters, alerting them to the safety risk, are expected to be mailed in October 2024. A second notice will follow once the software remedy is ready for deployment.

Until the fix is in place, Nissan advises owners to avoid using Level 3 quick charging stations and instead rely on slower charging methods, which do not present the same risk. For those affected, Nissan’s recall number is R24B2, and the corresponding NHTSA campaign number is 24V-700.

Fiat Spider Airbag Could Deploy With Excessive Force

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Chrysler (FCA US, LLC) has identified a software error in the airbag control module of certain 2017-2020 Fiat/Abarth 124 Spider vehicles. This issue can cause the airbags to deploy with excessive force during a crash, which poses a safety risk. As a result, these vehicles do not comply with the Federal Motor Vehicle Safety Standards (FMVSS) for occupant crash protection, specifically FMVSS No. 208, which governs crash protection and performance requirements for automotive airbags.

The problem came to light in July 2024, when Mazda Motor Corporation, a partner in the development of these vehicles, notified Stellantis Europe S.p.A. about a potential issue with the airbag control module. Mazda discovered this error during the development of new airbag sensors for upcoming vehicle models. As part of the research and testing process for these sensors, engineers identified a misconfiguration in the calibration tool used to program airbag control modules.

This discovery prompted Mazda to take a closer look at the settings of airbag control modules in previous models, including the 2016-2023 MX-5 Miata. During extensive simulation tests, Mazda engineers uncovered a potential flaw in the collision detection sensitivity of the airbag system. This flaw could cause airbags in these models to deploy improperly, failing to meet the safety standards designed to protect passengers from serious injury. The main concern is that the system might trigger the deployment of the dual-stage front airbag rather than the single-stage deployment that is appropriate for certain types of collisions. This misconfiguration increases the risk of neck injuries during a frontal crash.

FMVSS No. 208 requires that vehicles meet specific performance standards related to neck injury prevention during a 26 km/h frontal impact. The dual-stage airbag deployment in the affected Fiat/Abarth 124 Spider vehicles increases the force of the airbag during deployment, potentially leading to a higher risk of neck injuries, which would prevent the vehicles from meeting these safety requirements.

The issue is not related to a defective part, but rather a design oversight in the programming of the airbag control module. The voltage specifications for the accelerometer, a key component of the system that detects a crash and triggers the airbags, were incorrectly set. This misconfiguration leads to improper airbag deployment, which could result in the failure to meet safety regulations.

To remedy this issue, Chrysler will reprogram the airbag control module in all affected vehicles with the correct specifications. This software update will ensure that the airbags deploy at the appropriate force in the event of a crash, reducing the risk of injury and bringing the vehicles into compliance with federal safety standards.

Chrysler plans to begin notifying vehicle owners about the recall on November 7, 2024. Once notified, owners will be instructed to bring their vehicles to authorized dealerships for the airbag control module to be reprogrammed at no cost. In the meantime, Chrysler has assigned the recall number A3B to this issue, and the National Highway Traffic Safety Administration (NHTSA) has assigned it the campaign number 24V-694.

Mazda MX-5 Miata Air Bag Control Module Safety Concern

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Mazda will soon be reaching out to the owners of specific 2016-2023 Mazda MX-5 Miata vehicles due to a software issue affecting the airbag control module. This problem, first identified in April 2023, stems from a calibration error that may result in the front airbags deploying with excessive force during a crash. As a consequence, these vehicles fail to meet the Federal Motor Vehicle Safety Standards (FMVSS) for Occupant Crash Protection, potentially endangering the safety of both drivers and passengers.

Mazda became aware of the issue during the development of new airbag sensors for future models. During this process, engineers uncovered a misconfiguration in the calibration tool used to set up the airbag control modules. This discovery prompted Mazda to reevaluate and reassess the settings in control modules from earlier vehicle models. Through a series of rigorous simulation tests, Mazda found that the collision detection sensitivity in the 2016-2023 MX-5 Miata models could lead to improper airbag deployments that do not comply with safety standards.

The problem particularly arises during minor collisions, where the airbags may deploy with a force higher than intended. This excessive force poses an increased risk of injury to vehicle occupants, especially in situations where airbag deployment should be less aggressive. Although the issue seems isolated to the MX-5 Miata, Mazda has taken steps to conduct similar tests across other vehicle models to ensure that the problem does not affect a broader range of vehicles.

To resolve this issue, Mazda dealers will perform a software update on the Sophisticated Air Bag Sensor (SAS) control module of the affected vehicles. This update is designed to re-calibrate the airbag deployment system to meet FMVSS 208 standards, ensuring that airbags deploy at appropriate force levels in the event of a collision. Mazda has scheduled owner notification letters to be mailed starting November 17, 2024, alerting owners to the recall and the necessary repairs.

Mazda’s recall number for this issue is 6924I, and the National Highway Traffic Safety Administration (NHTSA) has assigned campaign number 24V-695 to this recall. It is crucial for MX-5 Miata owners to have their vehicles inspected and repaired as soon as possible. Doing so will not only bring the vehicles back into compliance with federal safety regulations but also ensure the continued safety of all passengers in the event of an accident.

Electrical Issues Affecting 2024 Ford Explorer and Bronco Sport Models

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battery problemsFord Motor Company has announced two significant recalls affecting its 2024 Explorer and Bronco Sport vehicles. Both recalls involve electrical issues that could potentially lead to serious problems for vehicle owners. Here’s what you need to know about each recall:

2024 Ford Explorer Recall (NHTSA Campaign Number: 24V-685)

Ford is recalling certain 2024 Explorer models equipped with 3.3L Hybrid engines. The issue stems from the 12-volt battery cable, which may chafe against the Belt-integrated Starter Generator (BiSG). If this occurs, it could lead to a short circuit.

This kind of electrical short can cause the vehicle to lose power, increasing the risk of a crash. In some cases, the short circuit could also result in a fire hazard. Ford is taking action to notify owners and replace or repair affected parts to ensure safety.

Key Concerns:

  • Affected Vehicles: 2024 Ford Explorers with 3.3L Hybrid engines
  • Problem: 12-volt battery cable could chafe against the BiSG, leading to a short circuit
  • Risks: Potential loss of power and fire hazard

2024 Ford Bronco Sport Recall (NHTSA Campaign Number: 24V-683)

The second recall involves certain 2024 Ford Bronco Sport vehicles. In these models, the body and powertrain control modules may fail to detect changes in the state of charge of the 12-volt battery. This issue can lead to incorrect readings and could affect the vehicle’s performance.

If the control modules fail to detect the battery’s actual charge, the vehicle may stall unexpectedly, which could increase the risk of an accident. Ford plans to update the control module software to fix the issue.

Key Concerns:

  • Affected Vehicles: 2024 Ford Bronco Sport
  • Problem: Control modules may not detect changes in the battery’s state of charge
  • Risks: Vehicle stalling unexpectedly, raising the likelihood of accidents

Ford will notify owners of the affected vehicles and instruct them to take their cars to authorized dealers for inspection and repair. The repairs, include replacing cables or updating control module software.

If you own a 2024 Ford Explorer Hybrid or Bronco Sport, it’s important to stay alert for communication from Ford about these recalls. In the meantime, you can also contact Ford’s customer service or visit the National Highway Traffic Safety Administration (NHTSA) website to check if your vehicle is part of the recall. By addressing these issues promptly, Ford aims to prevent potential accidents and ensure the continued safety of their customers.