Tag Archives: manufacturing defect

Audi Q5 Quattro Fire Risk: Improperly Tightened Cylinder Head Cover Screws

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Volkswagen Group of America, Inc. (Audi) has issued a recall for certain 2022-2024 Audi Q5 Quattro and Q5 Sportback Quattro vehicles due to a potential problem with the cylinder head cover screws. The screws may have been improperly tightened, which can cause them to loosen over time, leading to engine oil leaks from the cylinder head cover screw holes.

According to the defect report, the issue is attributed to varying tightening torques during the screwing process of the cylinder head cover, resulting in a potentially insecure screw connection and compromised sealing of the cylinder head cover. If engine oil comes into contact with hot parts of the engine, it can cause a fire. Owners are advised to be vigilant for signs of smoke in the engine compartment and to safely park their vehicle immediately if they notice any unusual odors or smoke.

The recall was prompted by customer complaints received by Audi in May 2023, which reported oil leaking from cylinder head covers of Audi Q5 2.0 TFSI vehicles. An investigation was launched, and a root cause analysis suggested that screws with burrs caused during the manufacturing process may have damaged the cylinder head cover surface, leading to oil leakage and potential torque reduction over time.

Despite implementing manufacturing improvements, Audi continued to monitor the field and recognized an increase in oil leak claims in early 2024. In response, the company issued a Technical Service Bulletin instructing dealers to inspect the cylinder head cover screws and replace any loose screws. Further analysis by the engine plant revealed the potential for improperly torqued cylinder head cover screws, leading Audi to review the screwing process with its supplier and implement changes.

However, despite these efforts, the U.S. market reported an increase in field claims of oil leakage and thermal event incidents between November and December 2024. Audi inspected and analyzed these cases, evaluating potential root causes and contributing factors. The company’s Product Safety Committee ultimately decided to conduct a safety recall for the affected vehicles on April 30, 2025.

To date, Audi has received 2,539 potentially related warranty claims of oil leaks in the U.S. and eleven thermal event cases. Early engine oil leaks can be difficult to detect, but advanced cases may be accompanied by an unpleasant odor or smoke in the engine compartment when the engine is hot.

To address the issue, dealers will inspect and replace the screws as necessary. Owner notification letters are expected to be mailed on July 8, 2025. The recall is identified by Audi’s number 15ZK and the NHTSA campaign number 25V-294. Owners of affected vehicles are advised to contact their local dealership for further information and to schedule an inspection and repair if necessary.

Hyundai Palisade Electric Oil Pump Issue

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Hyundai Motor America has announced a safety recall affecting a limited number of 2025 Hyundai Palisade vehicles due to a potential problem with the controller for the electric oil pump (EOP). The issue, which may cause an electrical short and increase the risk of a vehicle fire, is attributed to an insufficient seal on the EOP controller housing.

According to Hyundai, the problem was first identified in March 2025, when the company was notified of a potential issue involving the electric oil pump installed on a model year 2025 Palisade produced in Ulsan. An investigation revealed that a damaged spring in the tooling used during manufacturing may have compromised the hermetic sealing of the EOP controller housing, allowing moisture to accumulate on the printed circuit board and increasing the risk of electrical shorting.

The National Highway Traffic Safety Administration (NHTSA) was informed of the issue, and after reviewing the findings, Hyundai decided to conduct a safety recall of all affected model year 2025 Hyundai Palisade vehicles in the U.S. The recall aims to replace the EOP controller and associated wiring harness, if necessary, to prevent any potential fires.

Symptoms and Precautions

Drivers of affected vehicles may notice a burning or melting odor or an illumination of the Malfunction Indicator Light. While owners can continue driving their vehicles, Hyundai recommends parking them outside and away from structures until the recall remedy is completed as a precautionary measure.

Recall Remedy and Notification

Hyundai will notify all owners of the subject vehicles by first-class mail, instructing them to bring their vehicles to a Hyundai dealer for replacement of the EOP controller. The recall remedy is expected to begin on July 4, 2025. Owners can contact Hyundai’s customer service or visit the NHTSA website for more information on the recall.

The recall number assigned by Hyundai is 278, and the NHTSA campaign number is 25V-291. Affected owners are encouraged to follow the instructions provided in the notification letter to ensure their vehicle is repaired promptly and safely.

In conclusion, while the electric oil pump issue affects only a small number of 2025 Hyundai Palisade vehicles, it is essential for owners to be aware of the potential problem and take necessary precautions to prevent any accidents. By following the recommended steps and cooperating with Hyundai’s recall efforts, owners can ensure their vehicle is safe to drive and minimize any risks associated with this issue.

Engine Failure Problem Affects Certain GM Vehicles

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General Motors LLC (GM) has determined that certain 2021-2024 GM vehicles equipped with a 6.2L V8 gas engines could experience engine failure problems. The issue is caused by manufacturing defects in the connecting rod and/or crankshaft engine components, which can lead to engine damage and failure.

Affected Vehicles

The following GM vehicles are affected by this recall:

  • Cadillac Escalade (2021-2024)
  • Cadillac Escalade ESV (2021-2024)
  • Chevrolet Silverado 1500 (2021-2024)
  • Chevrolet Suburban (2021-2024)
  • Chevrolet Tahoe (2021-2024)
  • GMC Sierra 1500 (2021-2024)
  • GMC Yukon (2021-2024)
  • GMC Yukon XL (2021-2024)

The Problem

GM’s investigation found that the connecting rod and/or crankshaft engine components in these vehicles may have manufacturing defects, including:

  1. Rod-bearing damage from sediment on connecting rods and crankshaft-oil galleries
  2. Out of specification crankshaft dimensions and surface finish

These issues can cause or contribute to bearing damage, leading to loss of propulsion and engine failure.

Warning Signs

Drivers may be alerted to the condition prior to failure by:

  • Unusual engine noises (knocking, banging, etc.)
  • Illumination of the check engine light
  • Engine-performance issues, including:
    • Hesitation
    • High RPMs
    • Abnormal shifting
    • Reduced propulsion
    • No-start condition

Consequences of Engine Failure

If the engine fails during vehicle operation, the vehicle will lose propulsion, increasing the risk of a crash. In fact, GM has identified 12 potentially related alleged crashes and 12 potentially related alleged injuries in the U.S.

Recall Repair

Dealers will inspect the engine and, as necessary, repair or replace it. For vehicles that pass inspection, dealers will:

  • Add higher viscosity oil
  • Install a new oil fill cap
  • Replace the oil filter
  • Update the owner’s manual

Recall Details

  • GM’s recall number: N252494000
  • NHTSA campaign number: 25V-274
  • Owner notification letters are expected to be mailed on June 9, 2025

If you receive a notice saying your vehicle is affected, it is essential to take immediate action and contact your local dealer to schedule a repair. Remember to always monitor your vehicle’s performance and watch for any warning signs of engine failure.

Certain 2022-2024 Ford F-150 Lightning BEVs May Have A Battery Defect

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A potential safety issue has been identified in a small number of 2022-2024 Ford F-150 Lightning Battery Electric Vehicles (BEVs). The problem affects the high voltage battery cells, which may have a manufacturing defect that can cause an internal short circuit. This defect is due to misaligned electrodes in the battery cells, which can occur over repeated charge and discharge cycles.

The issue was first brought to Ford’s attention in October 2024, when a fire was reported in a 2022 model year F-150 BEV. Further investigation revealed two additional fires in 2022 and 2023 model year vehicles, prompting Ford to launch a broader inquiry into the matter. Although no physical samples were initially available for analysis, Ford’s Field Review Committee authorized a program to collect and evaluate additional samples from the field.

The subsequent tear-down analysis of the returned battery arrays revealed evidence of misaligned electrodes in the high voltage battery cells. The supplier also found that eight stacker machines between two production lines had produced cells with cathode shift, which did not meet the design requirements. This manufacturing concern resulted in overlap that fell short of the required standards. Notably, some of the cells from vehicles that experienced fires were manufactured during this time frame.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire and decided to approve a safety recall. The recall affects certain 2022-2024 Ford F-150 Lightning BEVs, and owners are advised to take precautions until the repair is completed. Specifically, owners should only charge their vehicles to a maximum of 80% battery capacity to minimize the risk of an internal short circuit.

To address this issue, dealers will inspect and replace the high voltage battery array as necessary. Owner notification letters are expected to be mailed on March 17, 2025. Ford’s recall number for this issue is 25S18, and the National Highway Traffic Safety Administration (NHTSA) has assigned a campaign number of 25V-131.

GM Wheel Lock-Up From Transmission Control Valve Defect

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General Motors (GM) has announced a safety defect affecting the transmission control valve in certain Chevrolet, GMC, and Cadillac vehicles equipped with diesel engines. The issue involves excess wear on the transmission control valve, which could lead to a gradual loss of pressure. This defect has the potential to cause harsh shifting, and in rare cases, a momentary lock-up of the rear wheels.

The Affected Vehicle Models Are:

2021 Cadillac Escalade
2021 Cadillac Escalade ESV
2020-2022 Chevrolet Silverado 1500
2020-2022 Chevrolet Silverado 2500
2020-2022 Chevrolet Silverado 3500
2021 Chevrolet Suburban
2021 Chevrolet Tahoe
2020-2022 GMC Sierra 1500
2020-2022 GMC Sierra 2500
2020-2022 GMC Sierra 3500
2021 GMC Yukon
2021 GMC Yukon XL

GM first became aware of this issue in June 2024 through the company’s Speak Up for Safety (SUFS) program, after a customer claimed that the rear wheels of a 2021 GMC Sierra 2500 HD pickup allegedly locked up while towing a trailer. The incident caused property damage to both the vehicle and the trailer. This report prompted GM to open a new investigation.

Previously, GM had already investigated the condition, finding that excessive wear in the transmission control valve could cause harsh downshifting and, in some cases, a momentary lock-up of the rear wheels. Earlier tests and analyses suggested that the lock-up was unlikely to lead to loss of vehicle control, and no accidents or injuries were reported at the time.

In July, the National Highway Traffic Safety Administration (NHTSA) notified GM that its Vehicle Owner Questionnaire (VOQ) monitoring process had flagged additional reports that could be related to this issue. GM’s investigators conducted an extensive analysis of these reports and reviewed comprehensive field data, identifying 1,888 field reports alleging a potential lock-up condition. Further examination revealed eleven specific incidents where the vehicles veered off the road, causing minor property damage. There were also three minor injuries reported, although none were linked to a collision.

Based on these findings, GM’s Safety Field Action Decision Authority (SFADA) decided in October to initiate a safety recall.

To address the defect, GM dealers will install updated transmission control module software. This software will monitor valve performance and detect signs of excess wear approximately 10,000 miles before a wheel lock-up condition could occur. If excess wear is detected, the software will limit the transmission to fifth gear, effectively preventing a wheel lock-up scenario, which typically happens during a downshift from eighth gear. Additionally, the vehicle’s instrument panel will display a service engine light and a reduced propulsion warning message to alert the driver. GM’s number for this recall is N242454440 and the NHTSA campaign number is 24V-797.

Hyundai Santa Fe Air Bag Warning Light

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In April 2024, Hyundai became aware of a significant safety issue involving the main floor wiring harness in certain 2024 Hyundai Santa Fe and Santa Fe Hybrid Electric Vehicle (HEV) models. This issue was first identified following reports of an inadvertent rear seat side airbag deployment in a Santa Fe vehicle in South Korea. As a result, Hyundai initiated a preliminary investigation, which was subsequently extended to include the North American market.

The defect centers on the main floor wire harness, which in the affected vehicles is susceptible to damage due to contact with the passenger-side, second-row bench seat’s folding hinge assembly. This contact can result in the wire harness becoming chafed, leading to several potential hazards:

  • Illumination of the Air Bag Warning Light: A damaged wire harness can trigger the air bag warning light on the vehicle’s dashboard, indicating a malfunction.
  • Inadvertent Air Bag Deployment: The damage can cause the airbags to deploy unintentionally, posing a significant risk to vehicle occupants.
  • Failure to Deploy Air Bags During a Crash: Conversely, the damage could also prevent the airbags from deploying in the event of a crash, reducing the effectiveness of this critical safety feature.

Hyundai’s investigation revealed eight unique incidents related to this defect in the U.S. market. These findings prompted the company to take immediate action to address the issue and ensure the safety of its customers.

Hyundai will notify affected vehicle owners via first-class mail, instructing them to bring their vehicles to an authorized Hyundai dealer for inspection and repair. The repair process will involve:

  1. Inspection of the Wire Harness: Dealers will check the condition of the main floor wire harness for any signs of damage.
  2. Securing the Wire Harness: If no damage is found, the harness will be properly secured to prevent future contact with the seat’s folding hinge assembly.
  3. Replacement of Damaged Wire Harness: If damage is detected, the wire harness will be replaced with a new one to ensure the vehicle’s safety systems function correctly.


As a precaution, Hyundai advises vehicle owners to be vigilant for any of the warning symptoms mentioned in the defect report, such as the air bag warning light illuminating. If any of these symptoms are present, owners are urged to immediately go for diagnosis and the necessary repairs.

Owner notification letters are scheduled to be mailed out on September 23, 2024. Hyundai has assigned the internal recall number 265 to this campaign, while the National Highway Traffic Safety Administration (NHTSA) has designated it as campaign number 24V-561.

Potential Engine Compartment Fire From Oil Leak In Jaguar and Land Rover Vehicles

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Certain 2024 Jaguar and Land Rover vehicles have been identified as being at risk for an oil leak within the engine compartment. An oil leak in the presence of an ignition source, such as hot engine components or exhaust parts, significantly increases the risk of a fire. This safety concern has prompted an investigation and subsequent recall to address the issue.

Jaguar Land Rover North America, LLC (Land Rover) first became aware of the problem in April 2024, following a field report that described an oil filter housing with a hairline crack. In response, Land Rover, along with the housing supplier, initiated a thorough investigation. Throughout April and May, the supplier reviewed the reported failures, inspected returned parts, and conducted extensive durability testing on the incorrect material parts. By June 7, 2024, the results of these tests were reported, and the Product Safety and Compliance Committee (PSCC) opened a formal investigation into the matter.

In June 2024, the Recall Determination Committee (RDC) concluded that the issue posed an unreasonable risk to safety, leading to the decision to launch a safety recall to remedy the affected vehicles. This decision was driven by the small number of fires reported as a result of the oil leak concern.

The following 2024 models have been identified as affected by this recall:

2024 Jaguar F-Pace
2024 Land Rover Defender
2024 Land Rover Discovery
2024 Land Rover Range Rover
2024 Land Rover Range Rover Sport
2024 Land Rover Range Rover Velar

Owners of these vehicles will receive official notices asking them to return to their dealers. The necessary repairs will involve replacing the filter housing, oil filter, and O-rings to ensure the safety and reliability of the vehicles. Jaguar’s reference number for this recall is H506, and the NHTSA campaign number is 24V-451. Land Rover’s number for this recall is N908 and the NHTSA campaign number is 24V-450.

Potential Shock Hazard From Tesla Charger Adapter

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If you are a Tesla owner and you have a Lectron Vortex Tesla Supercharger (NACS) to Combined Charging System (CCS) adapters in your vehicle, you may be contacted by Dropcases Ltd., regarding a potential problem affecting the safety of your charging system.

Some NACS to CCS adapters may not securely latch to the charger. An unsecured adapter may be disconnected without shutting off the charger power, increasing the risk of an electrical shock.

Dropcases LTD, the manufacturer of the adapters, became aware of the the problem in April 2024 when they saw a YouTube video showing a customer who was unable to latch their charging unit to a Tesla Supercharger. Dropcases LTD contacted the user, requesting the return of the adapter for evaluation and an internal investigation was initiated. It was determined that an error in the supplier’s processes resulted in a limited number of non-conforming units being shipped to customers, specifically within the first 1,121 units. Out of an abundance of caution, Dropcases LTD chose to recall the part.

According to the defect report, the adapters affected include certain Vortex Plug Tesla Supercharger to CCS Adapter 500A / 1,000V. The adapter enables charging at Tesla Supercharger stations for non-Tesla CCS1 electric vehicles. The issue affects the NACS latching mechanism on certain adapters.

Some units feature a latch pin that deviates from the intended design, impacting secure locking of the charger coupler. If the adapter does not latch securely, the charger coupler can potentially be forcibly removed by the user without depressing the NACS latch. If the adapter does not securely latch and a user attempts to disconnect it from the charger without releasing the NACS latch and cutting power from the charging station, there is a heightened risk of an electrical event, which could increase the risk of injury.

Dropcases Limited will be sending owners notification letters with instructions on how to get the adapter replaced. These letters are expected to be mailed May 3, 2024. NHTSA Campaign Number: 24E-033.