Tag Archives: electrical fire

Jeep Wrangler and Gladiator Potential Fire Risk From Steering Defect

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Owners of certain Jeep Wrangler and Jeep Gladiator vehicles should be aware of a significant safety defect affecting more than one million vehicles across North America. Chrysler (FCA US LLC) has announced Recall 21D (NHTSA Campaign Number 26V-363) involving certain 2021-2025 Jeep Wrangler and Jeep Gladiator models due to a defect in the electric hydraulic power steering pump (EHPSP) wiring system that could potentially lead to a vehicle fire.

What Is the Problem?

According to FCA US, under certain conditions, high-resistance electrical activity can occur at the connection point of the Electric Hydraulic Power Steering Pump (EHPSP). This increased electrical resistance can generate excessive heat, causing nearby combustible materials to overheat and potentially ignite.  What makes this defect particularly concerning is that a fire could occur even when the vehicle is parked and the ignition is turned off.

The issue originates from the electrical connection between the EHPSP and its wiring harness. Investigators discovered that some EHPSP components were manufactured outside specified tolerances, which could result in poor electrical contact. Over time, this can create excessive resistance, heat buildup, melting of the connector, and in rare cases, a vehicle fire.

Warning Signs Drivers May Notice

Before a failure occurs, some owners may experience symptoms related to the power steering system, including:

  • Loss of power steering assist
  • A “Service Power Steering” warning message
  • Diagnostic Trouble Codes (DTCs) related to the steering system

However, FCA notes that some incidents occurred without prior warning, which is one reason the recall was issued.

How the Investigation Unfolded

The road to this recall began in May 2023 when FCA US launched an investigation into reports of engine compartment fires in Jeep Wrangler and Gladiator vehicles. After reviewing available data through April 2024, the company initially closed the investigation, determining that the occurrence rate was low and did not represent an unreasonable safety risk.

That assessment changed in August 2024 when FCA began receiving an increased number of reports involving fires originating near the EHPSP electrical connection.  Shortly afterward, on September 6, 2024, the National Highway Traffic Safety Administration (NHTSA) opened a formal investigation, designated PE24-024, into engine compartment fires involving 2021-2023 Jeep Wrangler and Gladiator vehicles.

Over the next 18 months, FCA and NHTSA worked extensively to determine the cause of the fires. Engineers analyzed field reports, inspected returned parts, conducted vehicle buybacks, performed CT scans and X-ray analysis, tested materials, and carried out extensive laboratory and vehicle testing.

In spring 2025, investigators identified manufacturing tolerance issues in the EHPSP connector assembly. These issues could cause excessive insertion forces during assembly, resulting in spread terminals, incomplete electrical connections, and elevated electrical resistance. FCA also identified a separate “terminal push-out” condition that could contribute to poor electrical contact.

Although engineers initially struggled to duplicate the exact failure mode, FCA confirmed in April 2026 that a loose EHPSP electrical connection could generate enough heat to melt the connector and potentially ignite surrounding materials.

By May 2026, FCA was aware of:

  • 72 field reports related to the issue
  • 63 customer assistance records
  • 12 additional service records potentially related to the defect
  • 1 reported injury potentially associated with the condition

No accidents related to the defect had been reported.  

Based on the findings of the investigation, FCA’s Vehicle Regulations Committee formally determined on May 28, 2026, that a safety defect exists in affected vehicles.

What Should Owners Do?

FCA US is advising owners of affected vehicles to park their vehicle outside and away from structures, garages, and other vehicles until the recall repair has been completed.  This recommendation reflects the possibility that an electrical overheating event could occur even when the vehicle is parked and turned off.

Dealers will inspect the EHPSP connection and replace affected components as necessary at no cost to vehicle owners.

Owner notification letters are expected to begin mailing on July 9, 2026.

Recall Information

  • FCA Recall Number: 21D.
  • NHTSA Campaign Number: 26V-363.
  • Vehicles Affected: Approximately 1,076,999.
  • Defect: EHPSP electrical connection overheating.
  • Risk: Potential vehicle fire, including while parked.
  • Remedy: Inspection and replacement of affected parts as necessary.

If you own a 2021-2025 Jeep Wrangler or Jeep Gladiator, it is important to monitor recall announcements and schedule the repair as soon as it becomes available. While the number of reported incidents remains relatively small compared to the number of vehicles on the road, the potential consequences of an under-hood fire make this a recall that should not be ignored.

Hyundai Kona Potential Engine Compartment Fire From Short Circuit

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Hyundai Motor America (Hyundai) is initiating a recall for certain 2024 Kona models due to a potential risk of electrical short circuiting. This issue arises from the possibility of the battery cables rubbing against the engine control module bracket.

These vehicles are equipped with a 12-volt positive battery cable that could suffer damage during frontal collisions, leading to contact with the engine control module (ECM) bracket. This contact increases the likelihood of an electrical short, which could result in a fire in the engine compartment post-collision. Signs of this problem include smoke or a burning smell emanating from the engine area.

The issue first came to Hyundai’s attention in November 2023, following a report by the Insurance Institute for Highway Safety (IIHS) about an engine compartment fire in a 2024 Hyundai Kona 1.6T-GDI AWD during a crash test. The IIHS observed smoke and flames emerging from the engine area shortly after the test. Their preliminary assessment indicated a short circuit in the ECM, which led to repeated reignitions. The situation was resolved after disconnecting the auxiliary battery. This incident prompted NASO to launch a new investigation.

A joint examination by NASO, HMC, HATCI, and IIHS revealed damage to the alternator and 12-volt positive power wiring beneath the ECM, with exposed copper cores. The ECM bracket was found pressing against the 12-volt positive battery cable, believed to have shifted during the crash and caused the electrical short leading to the fires.

In response, Hyundai conducted crash tests in December with newly designed sheathing to protect the 12-volt positive wiring from shorting due to ECM bracket contact. These tests were successful, showing no damage or electrical shorting. Consequently, HMA’s NASO decided to recall the affected Kona vehicles.

To date, there have been no reported crashes, injuries, or deaths related to this issue, except for the single fire incident during the IIHS test. Hyundai is unaware of any field incidents. Vehicle owners will be notified to return their vehicles to Hyundai dealers for the installation of protective sheathing over the wiring. The recall is designated as number 252, with NHTSA campaign number 23V-900.

Chevy Express & GMC Savana HVAC Circuit May Overheat

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General Motors (GM) is one of the largest automobile manufacturers in the world, with a reputation for producing reliable and safe vehicles. However, like all automakers, GM occasionally identifies issues with its vehicles that need to be addressed to ensure the safety of its customers. Recently, GM identified a problem in certain 2003-2023 Chevrolet Express Cutaway and 2003-2023 GMC Savana Cutaway incomplete vehicles. These vehicles are equipped with wiring for an optional rear heating, ventilation, and air-conditioning (HVAC) system.

According to the defect report, these vehicles are equipped with an unused circuit that a final-stage manufacturer may elect to use to install an optional rear HVAC system. While this circuit is not typically used, if the final-stage manufacturer leaves the circuit’s connectors or cut wires unsealed, where exposure to moisture or contamination may, over time, cause corrosion. In rare cases, this corrosion could result in a high current draw through the circuit at the vehicles’ lower left side B-pillar. If left unaddressed, the problem could cause excessive heat in the circuit that could result in a fire.

To address this problem, GM began a product investigation in December 2022, after receiving reports of two alleged fire incidents involving a 2013 and a 2014 Chevrolet Express Cutaway incomplete vehicles. The company’s investigators analyzed inspection reports from the two subject vehicles and retrieved and analyzed field data for all Express Cutaway and GMC Savana Cutaway vehicles sold for model years 2005 through 2023, comprising approximately 167,000 units. Analysis of the field data, including legal claims, identified a total of eight potentially related complaints, six of which alleged fires.

On March 30, 2023, GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall. While the company is not aware of any accidents or injuries associated with this condition, it is taking this action to ensure the safety of its customers.

Owners of the affected vehicles will receive notices with instructions to return to their dealers to have the rear HVAC blower motor circuits at the left side B-pillar properly sealed. The recall is identified by GMC’s number N222386050 and the NHTSA campaign number is 23V-247.

2023 Kia Sportage Risk Of Electrical Fire

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Certain Kia Sportage SUVs manufactured between January 12, 2022, through August 8, 2022, may experience an electrical surge that could stall the engine and result in a vehicle fire.

Kia became aware of the problem in May 2022 when they received their first customer complaint of a no-start condition in a 2023 Sportage. An inspection of the vehicle found a loose alternator cable with thermal damage to the alternator, the wire harness, and the intake manifold. The affected parts were collected and sent for further inspection. In August, Kia received a second alternator collected from another incident that had localized melting around a broken alternator battery positive (B+) terminal due to electrical arcing. After inspection of the collected parts and a review of vehicle production records, Kia decided to initiate a recall.

According to the defect report, the alternator battery positive (B+) terminal nut may not have been properly torqued by the supplier during assembly. If the terminal nut is not properly torqued, it can loosen over time and may result in an engine stall. In the worst case, arching at the positive terminal could result in a vehicle fire. Drivers may be alerted of a problem through an illuminated Charging System Warning Light.

Owners receiving notices will be asked to return to their dealers to have the alternator battery positive terminal nut inspected and tightened as necessary. Kia’s number for this recall is SC248 and the NHTSA campaign number is 22V-651.

Earlier this month Kia issued a recall that included certain Kia Sportage vehicles that could catch fire. In this recall (22V-703) the car tow hitch harness could catch fire even when the car is parked. As part of the vehicle recall owners are asked not to park indoors or near structures.

Are you experiencing problems with your Kia vehicle? It could be a Lemon. Know your Lemon Law Rights. If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

A Dangerous Problem Worth Repeating
“Fire Warning For Chrysler Pacifica PHEV”

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Chrysler recommends that owners of select model year 2017-2018 Pacifica plug-in hybrid electric vehicles park their vehicles outdoors and away from other vehicles or structures due to a risk of fire, even if the vehicle is turned off. Owners are advised to NOT charge their vehicles and continue to park outside until a remedy is identified.

In August 2021, Chrysler Technical Safety and Regulatory Compliance Organization opened an investigation into a reported trend of fires in certain Chrysler Pacifica PHEVs. Since August 2021, there have been five customer records and twelve field reports relating to this issue. The potentially affected vehicles include 2017-2018 Chrysler Pacifica PHEVs manufactured between August 12, 2016, when production of Chrysler Pacifica PHEVs began, and ended on August 7, 2018, when the 2018 model year production ended. Chrysler will conduct a voluntary safety recall on all affected vehicles.

Although the automaker is still investigating the cause, the fire risk is likely due to corrosion of an electrical connection inside the Pacifica’s 12-volt battery system. This system is used to power auxiliary features, including radios and garage door openers, and is not part of the vehicle’s plug-in hybrid propulsion system. However, only hybrid vehicles are included in this recall.

According to the NHTSA defect report, “Certain 2017-2018 Chrysler Pacifica Hybrid vehicles may experience a fire, even with the ignition in the “OFF” mode. A vehicle fire can result in an increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.”

Because the remedy is under development, Chrysler is advising owners of these hybrid vehicles to refrain from recharging them and to park them away from structures and other vehicles. Owners can keep operating the vehicles using the internal combustion engine.

Toyota Tundra Headlight Electrical Connector Could Overheat

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Toyota will be asking owners of certain 2018-2021 Tundra trucks, to return to their dealership for a problem affecting the electrical circuits controlling the headlights in their vehicle.

The problem began in early April 2020 when Toyota received a field report alleging the headlamp connector on a subject vehicle overheated and caught fire. Since then, there have been 18 Toyota Field Technical Reports (12 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 6 alleging a flame at the headlamp assembly). There has also been 47 warranty claims (44 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 3 alleging a flame at the headlamp assembly).

According to the defect report, the subject vehicles are equipped with halogen headlamp electrical circuits that were designed incorrectly to allow the circuits for both the high and low beam bulb filaments to be energized simultaneously when the high beams are switched on. If the high beams are subjected to repeated extended use (e.g., continuously switched “on” in a commercial setting when the vehicle is idling or driving at low speed for extended periods of time and not allowing air flow to cool the headlamp connector), excess heat could lead to degradation of the bulb insulation and eventually the bulb connector. This can cause an open headlamp circuit, leading to an inoperative headlamp that can be noticed by the driver and repaired. However, if an open circuit does not occur, there is a possibility that the connector could continue to overheat, resulting in an increased risk of a fire.

Owners receiving notices will be asked to return to their dealers to have the engine wire harness assembly and headlight assembly inspected and replaced as necessary. Toyota’s numbers for this recall are 21TB06 and 21TA06 and the NHTSA campaign number is 21V-688.

2020 Ford F-150 Grinding Noise When Engine Starts

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Ford will be contacting a small number of 2020 Ford F-150 owners because of a problem with the electrical system in their trucks. According to the safety report filed with the NHTSA, the affected vehicles were built at their Kansas City assembly plant June 30, 2020 and July 1, 2020.

These trucks may have been built with a positive power supply cable nut that does not meet design specifications. These nuts do not have the correct torque characteristics or conductive coating needed at the power supply attachment to the starter motor. This could increase the amount of heat generated during starting and could create an electrical arch that could start a fire. Drivers will be alerted of a problem through grinding noises when starting or restarting during a stop-start event, or the engine may not start at all.

Owners receiving notices will be asked to return to their dealers to have the starter motor B+ power supply attachment nut replaced with the correct part. Ford’s number for this recall is 20S40 and the NHTSA campaign number is 20V-467.

2017-2020 Chrysler Pacifica Hybrid Safety Warning

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Fiat Chrysler Automobiles (FCA) have discovered that a safety defect exists in certain 2017-2020 Chrysler Pacifica Hybrid vehicles. Chrysler advises owners to take additional safety measures until the problem can be fixed by their dealership.

“Note: Consumers are advised to exercise the following precautions until the vehicle has the final repair completed: Do not park inside of buildings, near structures or other vehicles. Additionally, keep liquids out of the backseat area, including but not limited to beverages, wet items, umbrellas, or bottled liquids that may leak.”

According to the defect report, some 2017-2020 Chrysler Pacifica Hybrid vehicles may experience a high resistance electrical connection at the 12 volt isolator post. This high resistance could lead to prolonged heating and a potential vehicle fire even with the vehicle shut off.

A remedy for this recall is currently under development. In the meantime, notices will be sent out to owners instructing them to return to their dealers to have an interim inspection of this connection. If the inspection indicates the joint is compromised, owners will receive a loaner vehicle until a fix is developed.

Interim notifications are expected to begin around June 22, 2020. FCA US LLC’s number for this recall is W46 and the NHTSA campaign number is 20V-334.