Tag Archives: battery fire

Volkswagen ID.4 EV Safety Defect: Overheating Batteries

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Volkswagen has issued two separate safety defects affecting the 2023–2025 Volkswagen ID.4, its all-electric SUV. While both recalls involve safety-related defects, one affects a smaller subset of vehicles and the other impacts a much larger population of ID.4 owners.

Both recalls center on the vehicle’s high-voltage battery system, a critical and potentially dangerous component if defects arise. Battery-related issues are taken seriously by regulators due to the risk of overheating, fire, and loss of vehicle function.

For California drivers, repeated battery issues or extended repair times may also raise lemon law concerns.

Recall #1: High-Voltage Battery Overheating Risk

NHTSA Campaign Number: 26V028000
Volkswagen Recall Number: 93EW

Volkswagen is recalling a large number of 2023–2025 ID.4 vehicles due to a defect that may cause the high-voltage battery to overheat.

What Is the Problem?

Volkswagen has identified an issue in which certain battery cell modules may overheat, increasing the risk of a thermal event. Battery overheating in electric vehicles can potentially lead to:

  • Fire risk
  • Damage to the battery pack
  • Loss of vehicle functionality
  • Safety hazards during or after charging

Because of the seriousness of the risk, Volkswagen has issued immediate safety instructions for affected owners.

Important Safety Instructions for Owners

Until the recall repair is completed, owners are advised to:

  • Park the vehicle outside immediately after charging
  • Do not charge the vehicle indoors overnight
  • Avoid using Level 3 DC fast chargers
  • Limit the battery’s maximum charge to 80%

These precautions are intended to reduce the risk of overheating while Volkswagen prepares the permanent remedy.

Recall Remedy

Volkswagen dealers will:

  • Inspect the high-voltage battery
  • Replace affected battery cell modules as necessary

Owner notification letters are expected to be mailed on March 20, 2026.

Recall #2: High-Voltage Battery Software Defect

NHTSA Campaign Number: 26V030000
Volkswagen Recall Number: 93EA

A separate recall affects a smaller number of 2023–2025 Volkswagen ID.4 vehicles involving the high-voltage battery system.

What Is the Problem?

In this recall, Volkswagen identified a condition where the battery management software may not properly monitor or control battery behavior, which could contribute to overheating or other unsafe operating conditions.

Recall Remedy

To address the issue, Volkswagen dealers will:

  • Update the high-voltage battery software
  • Replace the high-voltage battery if necessary

As with the larger recall, owner notification letters are expected to be mailed March 20, 2026.

Why These Recalls Matter for California ID.4 Owners

Battery defects are among the most serious problems an electric vehicle can face. In California, EVs are protected under the Song-Beverly Consumer Warranty Act, commonly known as the Lemon Law.

You may have a potential lemon law claim if your Volkswagen ID.4:

  • Has repeated battery or charging-related issues
  • Requires multiple repair attempts for the same safety defect
  • Is out of service for an extended period due to recall repairs
  • Suffers diminished value or safety concerns even after repairs

Notably, recalls do not cancel lemon law rights. In fact, a safety recall involving a high-voltage battery can strengthen a claim if the defect substantially affects the vehicle’s use, value, or safety.

Bottom Line

Volkswagen’s two recalls for the 2023–2025 ID.4 highlight serious concerns involving the vehicle’s high-voltage battery system. While Volkswagen is offering repairs, owners should follow all safety guidance and carefully document any ongoing problems or time spent in the repair shop.

If your ID.4 continues to experience battery issues, charging limitations, or extended downtime, it may be worth exploring your rights under California Lemon Law.

2025 Volvo EX30 Battery Recall

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Volvo Cars has decided that there may be a safety defect affecting a small number of 2025 Volvo EX30 vehicles.  The potential issue involved the high-voltage battery. Although there have been no reported incidents, warranty claims, or service reports in the United States, the company is taking precautionary steps to reduce any possible safety risk while a permanent repair is developed.

The concern centers on the vehicle’s high-voltage battery cells. According to Volvo, a manufacturing process deviation may result in the formation of lithium plating growth inside certain battery cells. Over time, this condition can increase the risk of an internal short circuit, which in rare circumstances could cause the battery to overheat.

If such a short circuit were to occur, it could lead to a thermal event, meaning excessive heat and, in extreme cases, the possibility of fire. While this scenario is considered unlikely, Volvo determined the issue warranted a safety recall out of an abundance of caution.

Drivers may receive a warning if a problem develops. In affected vehicles, a battery overheating message would appear in the Driver Information Module, alerting the driver to the condition.

Volvo first became aware of the issue in July 2025, after receiving a report of potential high-voltage battery cell overheating outside the United States. The company launched an internal investigation, which was later escalated to its Critical Concern Action Process. After technical analysis and risk assessment by the Critical Concern Management Team, Volvo concluded that the issue could present an increased risk to motor vehicle safety. On December 26, 2025, the decision was made to issue a safety notification recall.

While the investigation continues, Volvo has issued interim guidance for affected owners. Customers are being advised to limit battery charging to a maximum of 70 percent state of charge and to avoid parking their vehicles indoors or near structures. These recommendations are intended to reduce battery stress and minimize potential risk until a final remedy is available.

Volvo is currently developing a permanent service solution. Future production has already been updated to include a new high-voltage battery variant designed to eliminate the condition. Owner notification letters are expected to be mailed beginning February 23, 2026, at which point dealers will provide further instructions.

This recall is identified by Volvo recall number R10355 and National Highway Traffic Safety Administration campaign number 26V-001.

If you own a 2025 Volvo EX30 and receive a recall notice, following the interim guidance and staying in contact with your dealer is the best course of action while the final repair is completed.

VW ID.4 Battery May Catch Fire

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Recall Reference: VW Campaign 93EV / NHTSA Campaign 25V-836

If you are the owner of a 2023 or 2024 Volkswagen ID.4, please take a moment to review this critical safety warning. Volkswagen has issued a recall for specific vehicles in this model range due to a high-voltage battery defect that could lead to a vehicle fire.

Because the risk involves the potential for a thermal event (fire) while the car is parked or driving, Volkswagen has issued specific “Park Outside” instructions while they prepare the remedy.

The Issue With The VW ID.4 Battery

The problem lies within the High Voltage (HV) battery. According to the defect report, a production deviation at a battery supplier resulted in misaligned electrodes within certain battery cell modules.  Specifically, the cathode inside the battery cell may have shifted. When these electrodes are not aligned correctly, it increases the risk of a short circuit inside the cell, which can lead to a fire.

Warning Signs

While a battery fire can happen suddenly, there are performance indicators you should watch for. If your vehicle has this defect, you may experience:

  • A noticeable loss of driving range.
  • A reduction in vehicle performance.

If you notice these issues, contact an authorized Volkswagen dealer immediately for diagnosis.

Critical Safety Instructions for Owners

Until the recall repair is performed, Volkswagen is advising owners of affected vehicles to follow these strict precautions to minimize risk:

  1. Park Outside: Park the vehicle away from structures and other cars immediately after charging.
  2. No Overnight Indoor Charging: Do not leave the vehicle charging indoors overnight.
  3. Limit Charge to 80%: Adjust your charging settings to stop at an 80% state of charge.
  4. Avoid Fast Charging: Do not use Level 3 DC Fast Chargers.

Timeline: How the Defect Was Discovered

The investigation into this issue spanned nearly two years. Here is a summary of the events that led to this recall:

  • January 2024 (Illinois): Volkswagen was notified of the first thermal event involving a vehicle connected to a Level 3 DC charger. The battery was analyzed, confirming the fire started in the HV battery.
  • July & October 2024 (California): Two separate fires occurred in parked vehicles that were not charging. Inspections confirmed the origin was the HV battery, but initial analysis (including CT scans by the supplier in June 2025) failed to identify the root cause.
  • December 2024 (Utah): A fourth thermal event occurred while a vehicle was being driven.
  • Summer 2025: With CT scans appearing inconclusive, VW and the supplier investigated other potential causes outside the battery but found nothing. The focus returned to the battery.
  • August 2025 (Colorado): A fifth event occurred while a vehicle was using a DC fast charger.
  • September 2025 (The Breakthrough): The supplier performed a physical “tear-down” analysis of damaged cell modules. They discovered the “shifted” electrode condition. By comparing this physical evidence back to the previous CT images, they realized the defect was visible in the scans but had been previously unrecognized.
  • November 2025: The supplier identified the specific batch of bad modules, allowing VW to isolate which vehicles were affected. On November 26, VW officially decided to issue a recall.

The Remedy

Dealers will resolve this issue by replacing the high-voltage battery cell modules as necessary. Owner Notification: Notification letters are expected to be mailed by January 30, 2026.

  • Volkswagen Recall Number: 93EV
  • NHTSA Campaign Number: 25V-836

Volvo Plug-In Hybrid 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.

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.

Posted in BMW.

Audi Announces High-Voltage Battery Issue In Certain PHEV Models

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Audi has announced a safety defect affecting certain high-voltage battery modules in its 2022-2023 Q5 Plug-in Hybrid Electric Vehicle (PHEV) and A7 PHEV models. The recall is necessary due to the risk of thermal events, which may cause smoke or even fires.

According to Audi, the root cause of the issue is still under investigation, but current analysis suggests that manufacturing deviations at a supplier of battery modules may be to blame. The company has been working closely with its supplier, Samsung SDI, and conducting comprehensive analyses of affected batteries to determine the conditions and circumstances that trigger thermal events.

The recall affects approximately 50 high-voltage batteries from non-U.S. markets, as well as an additional batch of batteries collected from field incidents in the United States. Audi has also received reports of other vehicles outside of these specific models, which are also under investigation.

To mitigate the risk, Audi plans to install advanced onboard diagnostic software, which will detect potential issues with battery module performance and alert the driver before problems may occur. The software is expected to be available in the second quarter of 2025.

In addition to the software update, Audi will offer two interim remedies for vehicles affected by this recall:

  1. Vehicles with online data: Affected modules or high-voltage batteries must be replaced.
  2. Vehicles without online data: Customers will be instructed not to charge their vehicle from external sources or via the combustion engine until the new software becomes available.

To date, Audi reports no injuries, crashes, or fires related to this issue in the United States market. Interim letters notifying owners of the safety risk will be mailed on January 24, 2025, with a second notice to follow once the final remedy is available.

Vehicles Affected:

  • 2022-2023 Audi Q5 PHEV
  • 2022 Audi A7 PHEV

Recall Numbers:

  • Volkswagen’s number: 93AA
  • NHTSA campaign number: 24V-898

Interim Remedies:

  1. Vehicles with online data: Replacement of affected modules or high-voltage batteries.
  2. Vehicles without online data: Instructed not to charge vehicle from external sources or via combustion engine until new software becomes available.

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.