Tag Archives: Electric Cars

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.

Volkswagen Charging Cable Could Overheat

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Volkswagen Group of America, Inc., particularly its Audi division, is facing a significant challenge with its 220V/240V charging cables. Owners of certain 2019-2024 Audi models are being notified due to a defect that could lead to the overheating and potential fire hazard of the outlet or charging cable. This alarming issue affects a range of models, including:

  • 2021-2022 Audi A7
  • 2020-2021 Audi A8
  • 2019-2024 Audi E-Tron
  • 2022-2024 Audi E-Tron GT
  • 2022-2024 Audi Q4 E-Tron
  • 2020-2024 Audi Q5
  • 2022-2024 Audi RS E-Tron GT

The problem first came to light in September 2020 when cases of melting and overheating at the industrial socket (NEMA 14-50) were reported during the use of the industrial 220V/240V plug with 40 amperes. Audi’s thorough investigation, which involved requesting parts from the field and analyzing customer charging behavior, revealed that the vehicles and the provided charging equipment were not at fault. Instead, the cause was often linked to household power outlets and wiring, or circuit breakers not capable of handling the required electrical current.

Understanding that household power outlets and wiring might not be equipped to handle the necessary current, Audi initiated a service campaign that instructed customers to bring their charging equipment to an Audi dealer to modify the charging system control unit to a 50% power level for the industrial plug. Additionally, a warning label was attached to the control unit of the Audi compact charging system, advising on safe usage.

Despite these measures, and the ability to charge at 100% current upon confirmation of adequate home power supply, further incidents of overheating and melting sockets were reported. As a result, in January 2022, Audi launched a safety recall, superseding the service campaign, to replace the affected charging cables with new ones equipped with temperature sensors. For unsold vehicles, the industrial charging cable will be replaced before delivery. As of the latest reports, Audi has identified 615 claims related to this issue from 08/05/2020 to 12/05/2023. Fortunately, there have been no reports of fires, crashes, or injuries connected to this problem.

Audi advises owners of the affected models not to use the 220V/240V compact/portable charging cable. Instead, they should use the 110V home charging cable or public charging stations until the issue is resolved. Owners can expect to receive interim notification letters by February 9, 2024, explaining the safety risks. A second notice will follow, detailing the availability of remedy parts, expected around mid-2024. Audi’s recall numbers are 93U6 and 93U8, with the NHTSA campaign number being 23V-842.

This recall underscores the importance of not only the quality of automotive products but also the compatibility and capacity of home electrical systems. Owners of the affected models are urged to heed the recall notices and take the necessary steps to ensure their safety.

LGES High Voltage Automobile Battery Fire Investigation

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Automotive Defect Investigation

The NHTSA have a continuing investigation into certain LGES high voltage batteries used in electric and hybrid vehicles. The investigation was prompted by the number of fire recalls on the electric and hybrid vehicles listed below. The purpose of this investigation is to find other companies that might have purchased the same or similar equipment from LG and to notify them if this defect has shown up in any vehicles they manufactured.

Recall No. 20V-107
Date: February 2020
Mercedes Benz USA notified NHTSA of a safety-related defect in one 2019 Smart ForTwo Electric Drive vehicle.
Note: This vehicle received an LG Chem high voltage battery that may contain a defect allowing for an electrical arc, which can ignite inside the battery cells, increasing the risk of a fire.

Recall No. 20V-630
Date: October 2020
Hyundai Motor America notified NHTSA of a safety-related defect in certain 2019-2020 Kona Electric vehicles. Note: The high-voltage battery system in the subject vehicles, supplied by LG, may have been produced with internal damage to certain cells of the lithium-ion battery increasing the risk of an electrical short circuit, which could result in a fire.

Recall No. 20V-701 & 21V-650
Date: November 2020
General Motors notified NHTSA of a safety defect in all 2017-2018 and certain 2019 Chevrolet Bolt EV vehicles.
Note: These vehicles were built with high voltage batteries, produced by LG, that may contain latent cell-level manufacturing defects posing a risk of fire when charged to full, or nearly full, capacity. In August 2021, GM expanded this recall to include certain 2020-2022 Chevrolet Bolt EV and 2022 Chevrolet Bolt EUV vehicles. GM stated, “the root cause of the failure is the simultaneous presence of two rare manufacturing defects in the same battery cell.”

Recall No. 21V-127
Date: March 2021
Hyundai notified NHTSA of a safety-related defect in certain 2019-2020 Kona Electric and 2020 Ioniq Electric vehicles .
Note: These vehicles are equipped with LG produced Lithium-ion battery cells where, if the Anode (Negative) tab is folded, the battery cell could allow the Lithium plating on the Anode tab to contact the Cathode resulting in an electrical short, thereby increasing the risk of a fire while parked, charging and/or driving.

Recall No. 22V-077
Date: February 2022
Chrysler notified NHTSA of a safety-related defect in certain 2017-2018 Pacifica Plug-In Hybrid Electric vehicles.
Note: These Pacifica vehicles contain hybrid battery packs produced by LG. FCA has not yet determined whether the battery packs were defective or the root cause of the fires.

Recall No. 22V-162
Date: March 2022
Volkswagen notified NHTSA of a safety-related defect in certain 2021 ID4 vehicles.
Note: The high voltage batteries used in the vehicles may contain insufficient soldering points and thus contain unreliable connections inside the high voltage battery. As a result of the unreliable connections, the vehicles may break down or stall while driving, leading to a crash.

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.

Ford Electric – Charge Cord Overheating

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Ford will be asking owners of certain 2013-2015 Ford C-Max Energi and Fusion Energi, and 2012-2015 Ford Focus Electric vehicles, to return to their dealers for a problem affecting the 120V convenience charge chord. (Cords affected include part numbers FM58-10B706-AA, FM58-10B706-AB, FM58-10B706-AC, FM58-10B706-AD, FM58-10B706-AE and FM58-10B706-AF.)

According to the defect report, the cord originally provided with these vehicles are missing a thermistor used to identify over temperature conditions. If the defective cord is used in combination with an AC outlet that is not on a dedicated circuit, is damaged, worn or corroded, it could experience an increased contact resistance and could overheat. Early indicators that a problem exists include: incomplete or slow charge cycles, inability to charge, burning odors or visible melting damage.

Dealers will replace the current cord with a new 120V convenience cord with a thermistor. Ford’s number for this recall is 18S24 and the NHTSA campaign number is 18V-592.

Government Incentives Recommended To Improve EV & Hybrid Sales

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According to a study done by the National Research Council (NRC), if electric and plug in hybrid vehicles are to be adopted by consumers, the Federal government must continue to provide incentives for buyers. Currently, vehicle cost, battery technology, and lack of consumer knowledge are some areas that the federal government need to address. Developing less expensive, better performing batteries to reduce cost, and a market strategy, is needed to create awareness and overcome customer uncertainty. Continue reading →

2012 Rav 4 EV Dead Battery? Lemon Law Buyback

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With only 5,000 miles on his new 2012 Toyota Rav 4 EV, a Manhattan Beach, CA resident started noticing problems related to the charging system of his vehicle. He would receive messages that the charging process had been interrupted or that the vehicle could not charge because of a malfunction. After six months of repeated repair attempts at a manufacturer approved repair facility, the RAV owner was told that there was no current fix for the problem. Frustrated with the lack of help in getting his vehicle repaired, he decided to contact the Law Offices of Delsack & Associates. Continue reading →