Tag Archives: fire risk

Pacifica Plug-In Hybrid Battery Fire Warning

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Chrysler Pacifica Battery FireChrysler (FCA US, LLC) has found a problem with some 2019-2021 Pacifica Plug-In Hybrid Electric (PHEV) vehicles, as well as some 2017-2018 Pacifica PHEVs that got a software update under a previous recall (NHTSA recall number 22V-077). The issue is with the battery pack, which could cause a fire even when the car is parked and the ignition is off.

Chrysler first learned about this issue in February 2022 through the Vehicle Regulations Committee, which led them to start a voluntary safety recall on certain Pacifica PHEVs, known as recall Z11.

Since then, Chrysler and LG Energy Solution (LGES) have been working to figure out the root cause of the problem. They’ve analyzed field reports, bought back vehicles, looked at vehicle data, conducted thermal tests, and torn down battery packs to get to the bottom of it.

In November 2022, the Technical Safety and Regulatory Compliance (TSRC) team at Chrysler was informed about a battery fire in a Pacifica PHEV that had already been fixed under recall Z11.

From June 2023 to December 2023, TSRC learned about five more fires involving the HV battery in some Pacifica PHEVs that had the Z11 remedy. They tried to buy back these vehicles to analyze if the recall fix was working.

In April 2024, Chrysler received a Pacifica PHEV with a post-Z11 remedy fire in the battery pack. After analyzing the vehicle and battery pack, they sent the battery back to the supplier for further inspection. They found a torn anode tab in one of the cells, but couldn’t identify a second factor causing the fires. This confirmed that the Z11 remedy wasn’t effective.

A folded or torn anode tab can lead to lithium by-product build-up over time. This defect, combined with another unknown factor, can cause an internal short in the battery pack, potentially resulting in a vehicle fire.

Chrysler advises owners not to charge their vehicles and to park them outside and away from structures until repairs are made. Dealers will update the high voltage battery pack control module (BPCM) software, and if necessary, replace the battery pack assembly. The recall numbers are 72B and 73B, and the NHTSA campaign numbers are 24V-356 and 24V-358. Vehicles previously repaired under recall 22V-077 will need to have the new fix applied.

Jaguar I-Pace EV Fire Risk When Parked

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Jaguar I-PaceIn a recent development, owners of 2019 Jaguar I-Pace vehicles are being urged to take immediate action due to a critical safety concern that could potentially lead to vehicle fires. The issue revolves around battery packs manufactured within a specific time frame, which have been identified as prone to technical faults, posing a significant risk of thermal overload.

The affected battery packs, produced between March 1, 2018, and May 31, 2018, have exhibited several technical deficiencies that increase the likelihood of short circuits within the battery cells. These short circuits generate excessive heat, particularly when the battery state of charge exceeds approximately 85%, ultimately triggering a thermal overload condition.

While some vehicles have undergone modifications through a previous safety recall (H441), mitigating the risk to some extent, Jaguar is ensuring the safety of all potentially affected vehicles and a new safety recall, identified as H484, has been initiated to address this critical issue.

The ramifications of a vehicle thermal overload event, such as fire or smoke, are severe and pose significant risks to occupants and bystanders alike. Occupant injury, damage to property, and even injury to persons outside the vehicle are potential outcomes of such incidents, underscoring the urgency of addressing this issue promptly and comprehensively.

In response to this safety concern, Jaguar has outlined interim measures for affected vehicle owners to mitigate the risk until a permanent solution is implemented. Owners are advised to park and charge their vehicles outdoors, away from structures, and to limit charging to a maximum of 75% state of charge. These precautions aim to minimize the risk of thermal overload incidents until the necessary repairs are completed.

Notification letters are scheduled to be dispatched to affected owners starting April 26, 2024. The recall process, identified by the National Highway Traffic Safety Administration (NHTSA) campaign number 24V-183, aims to rectify the underlying issue and ensure the safety and peace of mind of Jaguar I-Pace owners.

It’s imperative for owners of 2019 Jaguar I-Pace vehicles to heed this safety warning and comply with the manufacturer’s instructions promptly. Failure to address this issue in a timely manner could potentially lead to catastrophic consequences. Additionally, owners are encouraged to stay informed about further developments regarding the recall and to take appropriate action as advised by Jaguar and regulatory authorities.

NOTE: This recent safety recall, identified by NHTSA Recall Number 24V-183, is not the first instance where concerns regarding the same problem have been raised. Previous recalls, such as, NHTSA Recall Numbers 24V-085, 23V-709, and 23V-369, have also addressed issues related to thermal overload and potential fire hazards in Jaguar I-Pace vehicles. These recalls underscore the seriousness of the underlying technical issues and the manufacturer’s ongoing efforts to rectify them. Owners should be vigilant and proactive in responding to these recalls to ensure the safety and integrity of their vehicles.

Audi E-Tron Quattro Fire Risk From Overheating Battery Modules

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The Volkswagen Group of America, operating under its Audi brand, has recently identified a critical issue in a range of its electric vehicle models. This issue revolves around the charging system, specifically the high-voltage battery modules, raising concerns about potential overheating and fire safety risks.

Affected Models

The problem affects several Audi models between 2019 and 2024, including the RS e-tron GT, e-tron GT, Q4 e-tron Sportback, Q4 e-tron, Audi A8, e-tron Quattro, e-tron Sportback Quattro, Q5, and A7.

Overheating High-Voltage Battery Modules

The central issue lies in the high-voltage battery modules, which are prone to overheating. This has been especially evident when charging with the industrial 220V/240V plug at a current of 40 amperes. Crucially, Investigations revealed that the charging equipment itself was not at fault. Instead, the issue often stemmed from household power outlets and wiring incapable of handling the required current, leading to overheating of the home infrastructure.

Initial Discovery and Response

The issue first came to light in April 2020, following a fire incident outside the U.S. Audi collaborated with their high-voltage battery supplier, LG Energy Solutions, to investigate. By mid-2023, a noticeable increase in thermal events led to a deeper examination. Despite a service campaign in April 2022 that included a software update for cell module balancing, issues persisted.

Recall and Remedial Actions

In response, Audi initiated a voluntary global safety recall, designated 93U9 by Audi and 23V-867 by the NHTSA. The recall includes installing onboard diagnostic software to monitor battery module performance and replacing affected modules as necessary. Interim notification letters are scheduled for February 2024, with a detailed follow-up expected in the third quarter of the same year.

Charging Cable Replacement

A significant aspect of the recall is the replacement of the power cable used for industrial sockets (220V/240V/NEMA 14-50). The existing cable (part number 7PP971678 ED) will be replaced with a new design (part number 7PP971678GA), featuring temperature sensors. These cables should be available in the second quarter of 2024.

Safety Concerns and User Guidance

Owners of affected models are advised to be cautious, especially when using industrial sockets for charging. The overheating issue can cause not only damage to the charging cable but also pose a risk to household electrical infrastructure. If the problem exists, users may notice the charging cable feeling hot to the touch after use.

This recall underscores the importance of matching electric vehicle charging systems with compatible household wiring. Audi’s proactive steps in addressing this issue highlight their commitment to customer safety and the integrity of their electric vehicle line. Owners of the affected models are encouraged to heed recall notices and ensure their home charging setups are compatible and safe.

The charging issue identified in Audi’s electric vehicles bears notable similarities to the Chevrolet Bolt recall (21V-650). In both cases, the central concern revolves around the battery systems and the associated risk of overheating, which could potentially lead to fire hazards. The Chevrolet Bolt recall, much like Audi’s, involved issues with high-voltage battery packs that were found to be prone to catching fire. Both recalls necessitated substantial corrective actions, including software updates, close monitoring of battery performance, and in some cases, the replacement of battery modules. Furthermore, these incidents highlight a broader challenge in the electric vehicle industry, emphasizing the need for more robust and safe battery technologies and charging infrastructures. Such parallels underline the growing pains of electric vehicle technology and the critical importance of ensuring safety as these vehicles become increasingly prevalent.

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.

2019-2023 Jaguar I-PACE Potential Fire From Overheating Battery

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Jaguar Land Rover North America, LLC (Jaguar) is taking steps to address a potential safety concern involving certain 2019-2023 I-PACE vehicles. These vehicles were previously subject to recall 23V-369, but the earlier repairs may not have been executed correctly. This oversight could still leave the high-voltage battery at risk of overheating, potentially posing significant safety hazards.

Jaguar became aware of this issue in September 2023, triggered by a field report regarding a thermal overload incident in a vehicle that had previously undergone repairs as part of a prior recall (H441). An in-depth investigation into the matter revealed that the recall action for H441 had been mishandled by a retailer. In particular, the retailer had used an unauthorized service diagnostic tool, leading to the incorrect installation of essential software on the vehicle in question. Consequently, the safety defect persisted, even though the retailer had reported that the safety recall had been successfully completed.

This situation creates a lingering safety risk for affected vehicle owners. An improperly repaired vehicle continues to be vulnerable to conditions like thermal overload, which can result in potential fire or smoke issues. Such incidents can not only jeopardize the safety of vehicle occupants but also pose risks to individuals outside the vehicle and may cause property damage. What’s even more concerning is that the owners may remain unaware that the previous repair was not carried out correctly.

Fortunately, Jaguar is taking action to rectify the situation. Dealers will address the issue by updating the battery energy control module software, ensuring that the vehicles are brought up to the necessary safety standards. In the meantime, owners are strongly advised to park their vehicles outdoors and away from structures, as well as to charge them in the open until the recall repair is completed. This precautionary measure should be adhered to for 30 days after the repair has been finalized.

To help facilitate this important safety recall, Jaguar has assigned it the reference number H459, and it has been officially registered with the NHTSA under campaign number 23V-709.

Battery Fire Risk in Certain Lincoln Aviator and Ford Explorer Vehicles

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Ford Motor Company (Ford) is taking action to address a safety concern with specific 2020-2022 Lincoln Aviator and 2020-2022 Ford Explorer vehicles that are equipped with 3.0L PHEV (Plug-in Hybrid Electric Vehicle) engines. These vehicles may have a manufacturing defect in one or more of the high voltage battery cells, which could lead to an internal short circuit and a potential battery fire.

Discovery of the Issue

Ford became aware of this issue in June 2023 when they received a report regarding thermal venting problems with the PHEV battery used in these vehicles. The report highlighted a 2021 model year Transit Custom in France experiencing PHEV battery thermal venting. Subsequent analysis, conducted by the battery cell supplier, revealed an internal short circuit in the vehicle’s high voltage battery pack, partly due to the presence of a folded anode tab, which occurred during the cell manufacturing process.

Ongoing Investigation

The supplier’s investigation indicated that another, as yet unidentified, factor is necessary for the folded anode tab condition to lead to battery thermal venting. The supplier is actively conducting component-level testing to pinpoint this second factor. While this factor remains unknown, the Ford Critical Concern Review Group (CCRG) has been working to identify the group of vehicles that may potentially have the cell folded anode tab condition.

Additional Incidents

Ford was aware of three more instances of cells with folded anode tabs in the field. These incidents involved a 2020 model year Aviator in the United States, resulting in PHEV battery thermal venting, another 2020 model year Aviator in the United States resulting in a Malfunction Indicator Light (MIL) but no battery thermal venting, and a 2020 model year Aviator in Canada, also resulting in an MIL but no battery thermal venting.

Preventive Measures

To address this issue, Ford has reviewed the cell supplier’s manufacturing process and made improvements during cell production to reduce the occurrence of the folded anode tab condition. The timing of these process enhancements has been used by the CCRG to determine the affected population of vehicles.

Recall Procedure

Owners of the affected vehicles will be notified and requested to visit their authorized Ford dealers for a Battery Energy Control Module (BECM) diagnostic test. If the test identifies a battery problem, the high voltage battery pack will be replaced at no cost to the owner. To check if your vehicle is part of this recall, refer to Ford’s recall number 23S53 and the NHTSA campaign number 23V-626.

2020-2023 Jeep Wrangler Fuel Leak

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Some 2020-2023 model-year Jeep Wrangler vehicles may have been built with an unnecessary and unused frame stud that could puncture the fuel tank, potentially starting a fire. The suspect period began in October 2019, when frames with the extra frame stud were introduced into vehicle production, and ended on May 14, 2022, when frames with the frame stud were no longer used. The frames involved are Mopar Frame Assembly’s and the NHTSA Campaign Number is 23E-023.

The FCA Technical Safety and Regulatory Compliance (TSRC) opened an investigation into the problem as a result of an assembly plant report of some frames containing an extra frame stud. FCA reviewed supplier data, met with engineering to understand the frame design and change history, and review frame and vehicle measurement data. Although there have been no warranty claims or field reports related to the problem, the FCA TSRC have decided to conduct a recall on all affected vehicles.

According to the defect report, some Mopar frame assemblies may have been manufactured with an extra frame stud that, when installed in a vehicle, could contact the fuel tank. Over time, the problem could result in a fuel leak and an increased chance of a fire.

Owners receiving notices will be asked to return to their Chrysler dealer to have their vehicle inspected. If there is a potential problem, the frame stud will be removed and the area will be painted. FCA US, LLC’s number for this recall is 28A and the NHTSA campaign number is 23V-191.

If you are having repeated problems with your Jeep Wrangler and you think it could be a Lemon, or if you have any questions about your rights under the California Lemon Law, please call our office at 1-888-395-3666 or fill in the “Case Review” form at the top of this page, and get some great Lemon Law advice!

Chevy Bolt EV Potential Fire After Seat Belt Pretensioner Deployment

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General Motors (GM) has decided that a defect affecting seat belt safety exists in certain 2017-2023 Chevrolet Bolt EVs. GM will be contacting owners of affected vehicles with instructions to return to their dealership to have the problem corrected by installing fire barriers.

GM first became aware of the problem in September 2022 after receiving a report of a 2018 Chevy Bolt EV that experienced a fire. The fire seemed to originate in the right side lower pillar in the area of the pretensioner. GM opened an investigation into the incident and identified a total of three field incidents where exhaust from a deployed pretensioner ignited carpet fibers near the B-pillar. By December, GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall.

The problem arises during certain crash conditions that require the front seat belt pretensioners to deploy. According to the defect report, the temperature of the exhaust from a deployed pretensioner may be sufficient enough to ignite carpet and other materials in close proximity to the pretensioner.

Owners receiving notices will be asked to return to their dealership to have a metal foil barrier added between the carpet and pretensioner. Some vehicles will also require the installation of a pretensioner cover that will prevent the ignition of carpet material from pretensioner exhaust.

This recall will be launched in two phases, under bulletins N222383790 and N222383791. Notification to owners of vehicles that require only the installation of the foil barrier is estimated to begin on January 30, 2023. Owners of vehicles that also require installation of the pretensioner cover will begin receiving interim notification on January 30, 2023, with a second notification when parts become available. The NHTSA campaign number for this recall is 22V-930.

Chevy Bolt Seat Belt Pretensioner Fire