Category Archives: Lemon Alert

High Voltage Battery Plug Safety Issue in Certain 2022 Kia Niro EV’s

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2022 Kia Niro EV ChargingKia has identified a potential safety issue with certain 2022 Kia Niro Electric Vehicle (EV) models. The problem affects the high-voltage battery safety plug, which may overheat and melt due to electrical resistance.

What Happened?

The issue came to light in July 2023 when a dealer reported a case involving a 2022 Niro EV that shut off while driving without entering “Ready” mode. Further investigation revealed an isolated melted safety plug. Kia’s Safety Office monitored the issue and found no other incidents except for one isolated case.

What Did Kia Find?

Kia’s Safety Office conducted field data analysis and discovered that the melted safety plug was caused by high temperatures, not any issues with the battery cells or temperature sensors. The investigation also revealed a manufacturing process deviation in the supplier’s Female-Female terminal, which affected specific vehicle production lots.

Recall Alert

As a result of the findings, Kia has issued a recall for certain 2022 model year Niro EV vehicles due to the potential safety risk posed by the faulty safety plugs. The recall was announced on May 15, 2024.

Symptoms and Risks

If the electrical resistance in the safety plug occurs while driving or during battery charging, it may melt, increasing the risk of:

  • Loss of motive power
  • Fire

Drivers may notice an illuminated EV Service Warning light and/or a burning smell (melting plastics and smoke).

What to Do?

Owners with affected vehicles are advised not to charge their vehicle in a garage or any other covered structure until the recall repair is completed. Dealers will replace the safety plug, and owner notification letters are expected to be mailed on July 19, 2024.

Kia Recall Information

  • Kia’s number for this recall: SC314
  • NHTSA campaign number: 24V-358

Airbag Issue Affects Certain 2024 Jeep Grand Cherokee Models

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A recent discovery by FCA Technical Safety and Regulatory Compliance (TSRC) has led to a voluntary safety recall of certain 2024 Jeep Grand Cherokee vehicles. The issue affects a small number of vehicles that may be missing an important part in the front bumper. This missing piece could compromise the proper deployment of the front airbags.

The affected vehicles fail to comply with the Federal Motor Vehicle Safety Standards (FMVSS) for Occupant Crash Protection. FMVSS No. 208 specifies vehicle crash worthiness requirements and equipment requirements for active and passive restraint systems. In the event of a frontal collision, the missing energy absorbing foam could lead to a non-deployment or improper deployment of the front airbags, potentially increasing the risk of injury or harm to occupants.

According to FCA US, an analysis of vehicle production history revealed that some Jeep Grand Cherokee vehicles may have been built without a front fascia energy absorbing foam. This condition can lead to a non-compliance with FMVSS No. 208, as it compromises the intended load distribution or energy management, potentially jeopardizing proper crash sensing and airbag deployment.

The suspect period for affected vehicles began on December 6, 2023, and ended on December 9, 2023, when vehicle production processes were corrected. During this time, some Jeep Grand Cherokee vehicles may have been manufactured without the crucial foam, which is designed to absorb energy and help protect occupants in the event of a crash.

Dealers will inspect the affected vehicles and install the missing foam as necessary to ensure compliance with safety standards. This recall is intended to minimize any potential risks associated with this airbag issue and maintain the high standards of quality and safety that customers expect from Jeep vehicles.

Owners with affected vehicles will receive owner notification letters providing them with details on the recall and next steps to take. It is essential that vehicle owners take immediate action to address this issue and have their vehicles inspected and repaired as necessary to ensure their safety on the road.

Ford Hybrid – Unexpected Neutral Shifting

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Ford Escape GearshiftFord has discovered a problem affecting specific hybrid vehicles, including the 2022-2024 Maverick, 2020-2022 Escape, and 2021-2022 Lincoln Corsair models. These vehicles may contain software that could cause the vehicle to shift into neutral unexpectedly.

Investigation and Findings

In March 2024, Ford’s Critical Concern Review Group (CCRG) initiated an investigation following field reports indicating that some vehicles were shifting to neutral after receiving a Hybrid Powertrain Control Module (HPCM) software update at dealerships. The powertrain controls and calibration team discovered that the new Hybrid Transmission Internal Park Module (HTIPM) software, which had been released for service in January 2024, was incorrectly detecting noise in the Park Motor Position Sensor. This led to the generation of erroneous Park Motor Position Sensor Diagnostic Trouble Codes (DTCs) U1010 and U1011.

Field Action Approval

On May 3, 2024, Ford’s Field Review Committee examined the issue and approved a field action to address the problem. According to the defect report, the affected vehicles received HPCM software that could force the vehicle into a neutral state while driving. As the vehicle coasts to a stop, the transmission will automatically shift to “Park”. Despite this issue, drivers retain functionality for power braking and power steering. Once the driver shifts back to drive, the vehicle enters a limp home mode, which provides limited torque at low speeds up to 30 mph.

Reported Incidents and Warranty Claims

Ford has reported 315 warranty claims in North America and 125 Vehicle Owner Questionnaires (VOQs) that may be related to this software issue. These incidents highlight the importance of addressing the defect to ensure driver safety and vehicle reliability.

Recall Details and Owner Notification

To rectify the problem, dealers will update the HPCM software free of charge. Ford plans to mail owner notification letters starting on May 23, 2024. For reference, Ford’s recall number for this issue is 24S33, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-330.

Owners of the affected vehicles are encouraged to contact their dealers promptly to schedule the necessary software update. Ensuring that your vehicle receives this update is crucial for maintaining optimal performance and safety.

Summary

  • Affected Vehicles: 2022-2024 Ford Maverick, 2020-2022 Ford Escape, and 2021-2022 Lincoln Corsair hybrid models.
  • Issue: Software may cause unexpected shifts into neutral.
  • Investigation Start: March 2024 by Ford’s CCRG.
  • Findings: Noise in Park Motor Position Sensor detected by HTIPM software, causing erroneous DTCs U1010 and U1011.
  • Action Approved: May 3, 2024, by Ford’s Field Review Committee.
  • Incidents Reported: 315 warranty claims and 125 VOQs in North America.
  • Solution: HPCM software update by dealers.
  • Owner Notification: Letters to be mailed starting May 23, 2024.
  • Recall Numbers: Ford 24S33, NHTSA 24V-330.

2021-2023 Mini Cooper SE Vehicle Stall And Potential Battery Fire

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Mini CooperA manufacturing issue was identified in a small batch of 2021-2023 Mini Hardtop 2 Door Cooper SE vehicles. These electric cars were found to have a high voltage battery housing that did not meet the company’s assembly specifications. This discovery came to light after a concerning incident in the U.S. in October 2023, where one such vehicle experienced what is known as a thermal event—a significant overheating.

Following this incident, BMW initiated a thorough engineering analysis to pinpoint the cause. It was found that during certain production periods, there was a flaw in how the battery housing was sealed. Specifically, an inadequate amount of sealing compound was applied between the two halves of the battery module’s housing. This oversight made it possible for water to seep into the battery enclosure.

Water entering the high voltage battery compartment can trigger what is called an isolation fault. This type of fault compromises the battery’s integrity, leading to performance issues and safety concerns. Initially, such water ingress prompts the vehicle to display a warning message, alerting the driver of the fault and advising them to have the vehicle checked at a MINI service center.

Should the water exposure continue, the situation can escalate. The accumulation of moisture can cause multiple isolation faults, potentially causing the vehicle to stall. In more severe cases, particularly after long periods of inactivity, these faults could cause the battery to overheat significantly. Such overheating, while rare, could lead to a thermal event, even if the car is not in use.

To address this issue, BMW is recalling affected vehicles to inspect, and if necessary, repair the sealing of the battery housing. This includes a thorough leak test to ensure the integrity of the battery enclosure. Owners of the affected Mini Cooper SE models will be notified by mail with instructions to visit their dealer. Notification letters are scheduled to be sent out on June 21, 2024. The recall has been officially recorded under the NHTSA campaign number 24V-302.

Vehicle owners are encouraged to respond to the recall notice promptly to ensure their safety and the proper functioning of their vehicle.

Ford Bronco & Maverick Undetected Low Battery

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In recent years, advancements in automotive technology have led to increasingly sophisticated control systems within vehicles, aimed at enhancing performance, efficiency, and safety. However, with these advancements come the potential for unforeseen challenges and issues to arise.

One such challenge has been identified in certain models of Ford vehicles, specifically the 2021-2024 Ford Bronco Sport and the 2022-2023 Ford Maverick. The concern centers around the failure of the body control module (BCM) and powertrain control module (PCM) to accurately detect changes in the state of charge of the 12-volt battery. This oversight has significant implications, as it could result in a loss of drive power, thereby increasing the risk of accidents and compromising the safety of both drivers and passengers.

The issue first came to light in October 2023, when the National Highway Traffic Safety Administration’s Office of Defects Investigation (NHTSA ODI) initiated an inquiry following reports of loss of motive power (LOMP) and subsequent loss of 12-volt accessories in 2021 model year Bronco Sport vehicles. Upon receiving 29 potentially relevant Vehicle Owner Questionnaires (VOQs) from NHTSA, Ford’s Critical Concern Review Group (CCRG) promptly launched an investigation to delve deeper into the matter.

Subsequent testing and analysis revealed a fundamental flaw in the BCM and PCM calibrations, rendering them incapable of accurately detecting battery failure in the affected vehicles. This deficiency becomes particularly pronounced during instances where the alternator struggles to meet the electrical load demand or during Auto Stop-Start events. As a result, drivers may experience unexpected loss of drive power, posing a serious safety hazard.

In response to these findings, Ford’s Field Review Committee took decisive action and authorized a vehicle recall to address the underlying issue. Under the recall, authorized dealerships will undertake corrective measures by re-calibrating the BCM and PCM to ensure accurate monitoring of the 12-volt battery state of charge. The recall process is expected to commence soon, with owner notification letters slated to be mailed out on May 13, 2024.

However, the implications of this issue extend beyond the immediate safety concerns. Ford acknowledges a significant number of warranty reports, field reports, and customer complaints related to this issue, totalling 917, 11, and 54 respectively. Moreover, there have been alarming reports of three unverified incidents of fire and two property damage claims allegedly linked to this concern. These statistics underscore the urgency of addressing the issue promptly and comprehensively.

In light of these developments, Ford has assigned a unique recall number, 24S24, and the corresponding NHTSA campaign number is 24V-267.

Airbag May Not Deploy In Subaru Outback And Legacy Vehicles

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This matter came to light in February 2024 when Subaru initiated an investigation after receiving returned parts from reports indicating airbags failing to deploy as intended. Subaru collaborated with the supplier and submitted an equipment recall (24E-016) to the National Highway Traffic Safety Administration (NHTSA), signalling the commencement of evaluations regarding the safety implications for Subaru vehicles and the potentially impacted population. Subaru made the decision in March to launch a comprehensive safety recall campaign.

Digging into the technicalities of the issue, the defect report highlights a convergence of factors contributing to the capacitor cracking. It suggests that the utilization of alternate component sub-suppliers during short-term natural disaster recovery, combined with certain supplier processing methods, may have led to this vulnerability. Specifically, it’s noted that during a specific production period at a particular supplier, the ODS Sensor Printed Circuit Board (PCB) might have undergone deformation, thereby initiating cracks in the capacitor. Over time, these cracks could permit moisture ingress into the capacitor, ultimately resulting in a short circuit.

The ramifications of this malfunction are significant. When a short circuit occurs, indicators such as the SRS airbag system warning lamp and the front passenger’s frontal airbag OFF indicator illuminate. This signifies a potential failure of the front passenger airbag to deploy in specific crash scenarios, thus elevating the risk of injury to the occupant in the respective seat.

In response to this concern, Subaru has outlined a comprehensive course of action. Owners of the affected vehicles will be contacted and requested to visit authorized dealerships for the replacement of ODS sensors on the front passenger seat. Initial communication regarding the safety risk is anticipated to be dispatched by May 21, 2024, in the form of interim letters. A subsequent letter will follow once the remedy procedure is finalized. To facilitate communication and tracking, Subaru has assigned the recall number WRA-24, with the NHTSA campaign number denoted as 24V-227.

Jaguar I-Pace EV Fire Risk When Parked

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Jaguar I-PaceIn a recent development, owners of 2019 Jaguar I-Pace vehicles are being urged to take immediate action due to a critical safety concern that could potentially lead to vehicle fires. The issue revolves around battery packs manufactured within a specific time frame, which have been identified as prone to technical faults, posing a significant risk of thermal overload.

The affected battery packs, produced between March 1, 2018, and May 31, 2018, have exhibited several technical deficiencies that increase the likelihood of short circuits within the battery cells. These short circuits generate excessive heat, particularly when the battery state of charge exceeds approximately 85%, ultimately triggering a thermal overload condition.

While some vehicles have undergone modifications through a previous safety recall (H441), mitigating the risk to some extent, Jaguar is ensuring the safety of all potentially affected vehicles and a new safety recall, identified as H484, has been initiated to address this critical issue.

The ramifications of a vehicle thermal overload event, such as fire or smoke, are severe and pose significant risks to occupants and bystanders alike. Occupant injury, damage to property, and even injury to persons outside the vehicle are potential outcomes of such incidents, underscoring the urgency of addressing this issue promptly and comprehensively.

In response to this safety concern, Jaguar has outlined interim measures for affected vehicle owners to mitigate the risk until a permanent solution is implemented. Owners are advised to park and charge their vehicles outdoors, away from structures, and to limit charging to a maximum of 75% state of charge. These precautions aim to minimize the risk of thermal overload incidents until the necessary repairs are completed.

Notification letters are scheduled to be dispatched to affected owners starting April 26, 2024. The recall process, identified by the National Highway Traffic Safety Administration (NHTSA) campaign number 24V-183, aims to rectify the underlying issue and ensure the safety and peace of mind of Jaguar I-Pace owners.

It’s imperative for owners of 2019 Jaguar I-Pace vehicles to heed this safety warning and comply with the manufacturer’s instructions promptly. Failure to address this issue in a timely manner could potentially lead to catastrophic consequences. Additionally, owners are encouraged to stay informed about further developments regarding the recall and to take appropriate action as advised by Jaguar and regulatory authorities.

NOTE: This recent safety recall, identified by NHTSA Recall Number 24V-183, is not the first instance where concerns regarding the same problem have been raised. Previous recalls, such as, NHTSA Recall Numbers 24V-085, 23V-709, and 23V-369, have also addressed issues related to thermal overload and potential fire hazards in Jaguar I-Pace vehicles. These recalls underscore the seriousness of the underlying technical issues and the manufacturer’s ongoing efforts to rectify them. Owners should be vigilant and proactive in responding to these recalls to ensure the safety and integrity of their vehicles.

Hyundai Genesis Oil Feed Pipe Leak

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Hyundai Motor America (HMC) is reaching out to owners of specific Genesis G70, G80, and G90 vehicles equipped with a 3.3-liter V6 turbocharged engine about a crucial safety concern. This issue involves the oil feed pipe that could potentially deteriorate and lead to oil leakage, posing a risk of engine compartment fires.

What’s the Problem?

The defect lies in the left hand (LH) turbocharger oil supply pipe within these vehicles. Prolonged exposure to high temperatures in the engine compartment can cause this pipe to crack, potentially resulting in oil leaks onto the exhaust manifold. Such leaks significantly increase the risk of engine compartment fires.

Investigation and Decision to Recall

HMC initiated an investigation into this issue in June 2023 after reports of similar incidents in foreign markets. The Data Review Committee (DRC) noted a concerning trend of turbocharger oil supply pipe repairs during colder seasons. After escalating the investigation to the Technical Review Committee (TRC) in February 2024, HMC confirmed the need for a safety recall.

The TRC observed repeat repairs related to a prior recall (Recall 003G – 19V-538) addressing oil leak issues caused by insufficient swaging of the turbocharger oil supply pipe fitting. The affected vehicles, including those addressed in the previous recall, were manufactured before a material change to stainless steel pipes was implemented by the supplier around August 2021.

Affected Vehicles and Reports

The recall affects approximately:

  • 14,186 model year 2019-2022 Genesis G70 vehicles
  • 7,372 model year 2018-2020 Genesis G80 vehicles
  • 6,881 model year 2017-2022 Genesis G90 vehicles

As of January 15, 2024, HMC has received 81 reports alleging the defect in the U.S. market. However, no confirmed crashes, injuries, or fires related to this issue have been reported.

Signs of Trouble

Owners should remain vigilant for signs indicating a potential problem with the oil feed pipe, including:

  • White smoke
  • Burning smell
  • Oil leaking onto ground surfaces

What Next?

All affected vehicle owners will receive notification by first-class mail, providing instructions to visit a Genesis retailer for replacement of the LH turbocharger oil supply pipe. The recall number assigned to this issue is 019G. The NHTSA campaign number is 24V-191, replacing the previous recall number 19V-538. Vehicles previously serviced under recall 19V-538 will require another repair.