Tag Archives: battery overheat

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.

Battery Cell Problems In Ford Escape & Lincoln Corsair Plug-In Hybrids

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Ford has decided that a safety defect exists involving the high-voltage battery packs inside certain plug-in hybrid vehicles—specifically the 2020–2024 Ford Escape PHEV and 2021–2024 Lincoln Corsair PHEV.  At the center of the issue is a manufacturing defect inside one or more battery cells, which can lead to an internal short circuit and, in the worst cases, battery thermal venting or vehicle shutdown.

This problem originally surfaced years ago, was addressed by a previous recall, and now—based on new field data—Ford has determined that the prior fix may not have been enough.

What’s Causing the Problem?

Inside the high-voltage battery pack, each cell has a separator layer that keeps the cathode and anode apart. If this thin separator layer becomes damaged, the cell can short internally.  Ford, its engineering teams, and the battery cell supplier have all pointed to variability in the supplier’s production process as the likely cause. This inconsistency may lead to small imperfections or weaknesses in the separator layer.

When the separator is compromised, the result can be:

  • Internal short circuits
  • Loss of propulsion power
  • Battery overheating
  • Thermal venting
  • Potential vehicle fire

Ford has not yet identified the complete root cause. Tear down investigations are still ongoing.

Safety Risks: What Can Happen

If a battery cell shorts internally:

1. Loss of Motive Power While Driving

The vehicle may suddenly shut down its propulsion system.
A red “Stop Safely Now” warning appears on the instrument cluster.

Although steering, braking, and lights still work, a sudden loss of acceleration dramatically increases crash and injury risk.

2. Battery Thermal Venting / Fire Risk

A shorted cell can overheat and vent hot gas, which can ignite surrounding components.
This is a significant safety hazard, particularly if venting occurs during or after charging.

To date, Ford reports no injuries or accidents connected to this defect.

A Look Back: The 24V-954 / 24S79 Recall

Ford already attempted to fix this issue once.

In December 2024, Ford approved recall 24V-954 (Ford) / 24S79 (Lincoln), which rolled out the following remedy:

  • Updated Battery Energy Control Module (BECM) software
  • Added enhanced detection of battery cell anomalies
  • Stopped battery charging automatically if anomalies were detected
  • Alerted owners through messages in the instrument cluster

This fix was intended to catch separator-layer damage before it caused a short circuit.  However, new field reports show this strategy was not always effective.

The Turning Point: New Thermal Venting Cases in 2025

July–August 2025

Three European Ford Kuga PHEV vehicles (the Kuga is the European variant of the Escape PHEV) experienced battery thermal venting even AFTER receiving the recall software update.

September 2025

Two more cases surfaced.

August–October 2025 Investigation

Ford’s Critical Concern Review Group (CCRG) opened a formal investigation on August 27, 2025.
Recovered battery packs and control modules showed:

  • No detectable anomalies before venting
  • Significant thermal damage making root-cause confirmation difficult
  • The updated software did NOT trigger any warnings prior to failure

Meanwhile, tear down analysis from other replaced battery packs (those that were flagged by the software and did not vent) has not yet identified a definitive cause.

As of November 5, 2025

Ford reports:

  • 7 total venting incidents, all from European Kuga PHEV vehicles
  • All had already received the 24V-954 software update
  • No injuries or accidents

November 7, 2025

Ford approved a new field action—leading to today’s recall.

The New Recall: 25SC4 (Ford) / 25V-789 (NHTSA)

Because of the new cases, Ford has issued a new recall to replace the old one.

Affected Vehicles:

  • 2020–2024 Ford Escape Plug-In Hybrid
  • 2021–2024 Lincoln Corsair Plug-In Hybrid
    (These vehicles were previously included in recall 24V-954.)

Ford’s New Instructions to Owners

Until the final fix is ready, Ford advises:

  • Only use Auto EV mode
  • Limit the maximum charge of the high-voltage battery
  • Wait for mailed instructions and further updates

Interim owner letters are scheduled to go out December 1, 2025, detailing the safety risks and how to limit battery charging.  A second letter will follow once a permanent remedy is available.

The Final Remedy Is Still Under Development

Ford has not yet determined what the permanent fix will look like—likely because the underlying defect is still not fully understood.

Conclusion

Ford’s latest recall highlights an unresolved and potentially serious defect in the high-voltage battery cells used in its Escape and Corsair plug-in hybrid models. The original software-based solution from 2024 was not enough to catch every instance of cell separator damage, and new thermal-venting cases have forced Ford to develop a more comprehensive fix.  Until that final remedy is completed, owners must limit charging, follow Ford’s interim instructions, and watch for important recall notices.

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.

Jaguar I-Pace Battery Could Overheat

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Jaguar Land Rover North America, LLC (Jaguar) are reaching out to the owners of specific 2019 Jaguar I-PACE vehicles regarding a significant safety concern involving the high-voltage battery. The issue, which could potentially cause the battery to overheat, has prompted a recall to ensure the safety of the vehicle owners.

This recall comes after a series of events beginning in July 2024, when Ford’s Critical Concern Review Group identified a problem related to a warranty report. The issue involved a fuel injector with a missing o-ring support disc, which could lead to fuel system malfunctions. Ford’s Supplier Technical Assistance team, in collaboration with the supplier, conducted an in-depth review of images taken during the production of all fuel injectors to pinpoint the parts that could be affected. They then compared these findings to vehicle production records to identify the specific vehicles at risk.

On August 16, 2024, Ford’s Field Review Committee evaluated the concern and decided to approve a field action to address the problem. Up to that date, Ford had identified 10 reports of vehicles with fuel injectors missing the crucial o-ring support disc. Fortunately, there have been no reports of fires, accidents, or injuries related to this condition. However, the potential risk was significant enough to warrant immediate action.

Jaguar is advising all affected vehicle owners to take precautionary measures until the recall repair is completed. Specifically, owners are urged to park and charge their vehicles outdoors and away from any structures. This precaution should continue for 30 days even after the repair has been completed, ensuring the safety of both the owners and their surroundings.

As an interim solution, Jaguar dealerships will update the software of the battery energy control module to help mitigate the risk. However, the final, long-term remedy for the issue is still being developed. Jaguar plans to send out official owner notification letters by October 18, 2024, providing detailed instructions on the next steps. For reference, Jaguar has assigned the recall number H514, and it has been registered with the National Highway Traffic Safety Administration (NHTSA) under the campaign number 24V-633.

It’s important to note that this isn’t the first recall related to this issue. The same vehicles were previously recalled under multiple recall numbers, including 24V-085 (H471), 23V-709 (H459), and 23V-369 (H441). If you own one of these vehicles, you will need to have the latest remedy performed, even if your vehicle has already undergone previous repairs for this issue.