Tag Archives: manufacturing defect

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.

Airbag May Not Deploy In Subaru Outback And Legacy Vehicles

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This matter came to light in February 2024 when Subaru initiated an investigation after receiving returned parts from reports indicating airbags failing to deploy as intended. Subaru collaborated with the supplier and submitted an equipment recall (24E-016) to the National Highway Traffic Safety Administration (NHTSA), signalling the commencement of evaluations regarding the safety implications for Subaru vehicles and the potentially impacted population. Subaru made the decision in March to launch a comprehensive safety recall campaign.

Digging into the technicalities of the issue, the defect report highlights a convergence of factors contributing to the capacitor cracking. It suggests that the utilization of alternate component sub-suppliers during short-term natural disaster recovery, combined with certain supplier processing methods, may have led to this vulnerability. Specifically, it’s noted that during a specific production period at a particular supplier, the ODS Sensor Printed Circuit Board (PCB) might have undergone deformation, thereby initiating cracks in the capacitor. Over time, these cracks could permit moisture ingress into the capacitor, ultimately resulting in a short circuit.

The ramifications of this malfunction are significant. When a short circuit occurs, indicators such as the SRS airbag system warning lamp and the front passenger’s frontal airbag OFF indicator illuminate. This signifies a potential failure of the front passenger airbag to deploy in specific crash scenarios, thus elevating the risk of injury to the occupant in the respective seat.

In response to this concern, Subaru has outlined a comprehensive course of action. Owners of the affected vehicles will be contacted and requested to visit authorized dealerships for the replacement of ODS sensors on the front passenger seat. Initial communication regarding the safety risk is anticipated to be dispatched by May 21, 2024, in the form of interim letters. A subsequent letter will follow once the remedy procedure is finalized. To facilitate communication and tracking, Subaru has assigned the recall number WRA-24, with the NHTSA campaign number denoted as 24V-227.

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.

Seat Belt Issue in Certain GMC Hummer EVs

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General Motors (GM) has recently identified a significant safety defect in some of its electric vehicles (EVs). This issue, affecting specific 2023-2024 model year GMC Hummer EV Pickups, 2024 GMC Hummer EV SUVs, and certain 2024 Chevrolet Silverado EVs, revolves around a crucial component of vehicle safety: the seat belt.

Discovery and Investigation of the Defect

In August 2023, a GM seat engineer, utilizing the company’s Speak Up for Safety (SUFS) program, reported a potential flaw after being alerted by GM’s seat supplier. The concern was about a loose front seat belt buckle bolt in a seat built for a 2024 HUMMER EV. This prompted GM to initiate a thorough product investigation.

Working closely with the supplier, GM discovered that the assembly process might not have been consistently adhered to, leading to possible out-of-sequence torquing of seat frame assembly bolts. This irregularity could result in the seat belt buckle attachment bolt not being tightened to the required specifications. After reviewing the supplier’s manufacturing records, GM identified seat frame assemblies that deviated from the intended assembly order.

Upon inspecting 754 suspect seats, GM and the supplier found two seats with improperly torqued attachment bolts. Fortunately, as of now, GM is not aware of any accidents or injuries related to this condition.

The Importance of Seat Belt Safety

The seat belt is a fundamental safety device in any vehicle, designed to protect occupants in the event of a collision or sudden stop. A properly functioning seat belt system can significantly reduce the risk of serious injury or death during an accident. It’s a vital line of defence, ensuring that passengers are securely restrained and minimizing their movement during a crash.

The Recall and Corrective Measures

In November, GM’s Safety and Field Action Decision Authority decided to conduct a safety recall. Vehicle owners will be notified and advised to return to their dealers for inspection. The specific focus will be on tightening the left and right front seat belt buckle attachment bolts.

Owners of affected vehicles may notice a rattle near the seat belt buckle, signalling the potential issue. It is crucial for owners to heed this warning and take prompt action.

GM has designated the recall number as N232419280, and it is also recognized under the National Highway Traffic Safety Administration (NHTSA) campaign number 23V-786.

This recall by GM underscores the importance of stringent quality control and responsive safety measures in the automotive industry. The seat belt, a simple yet vital safety component, must meet the highest standards of reliability. GM’s action in addressing this issue serves as a reminder of the ongoing need for vigilance and regular vehicle maintenance to ensure the safety of all road users.

Loss Of Drive Power From Fuel Pump Failure

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Hyundai is taking action to address a fuel pump issue in certain 2021-2022 Genesis vehicles. This problem came to Hyundai’s attention in September 2022 when they received their first warranty claim related to a 2022 Genesis GV70 vehicle experiencing a stall / hesitation problem. As more warranty claims started pouring in, Hyundai launched an investigation to pinpoint the root cause of the issue.

The vehicles affected include:

  • 2021-2022 Genesis G80
  • 2022 Genesis GV70
  • 2021-2022 Genesis GV80

In June 2023, Hyundai successfully replicated the problem. Their investigation, which included a dimensional tolerance CT scan, revealed a potential problem: interference between the impeller (a key component of the fuel pump) and its housing, causing an obstruction. Hyundai collaborated with the supplier and identified a specific production lot of fuel pump assemblies that lacked sufficient impeller material. This issue potentially affected vehicles manufactured between June 2021 and December 2021. Consequently, Hyundai made the decision to initiate a recall.

The issue lies with the low-pressure fuel pump assemblies in these vehicles. Some of these assemblies may contain impellers that do not meet the required material specifications, which can lead to deformations. This deformation can result in the impeller interfering with the fuel pump housing, creating mechanical resistance that can cause the fuel pump to shut down.

A fuel pump shutdown can severely restrict the flow of fuel to the engine, potentially causing a sudden reduction or complete loss of power while driving. This poses an increased risk of accidents.

As of the latest available data up to August 22, 2023, Hyundai has received reports of 879 unique incidents related to this defect condition in the United States, spanning from July 1, 2021. Fortunately, there have been no confirmed crashes, fires, or injuries linked to this fuel pump issue.

To rectify the problem, authorized Hyundai dealers will replace the affected fuel pumps. The recall associated with this issue is identified by Hyundai as number 016G, and it has been assigned the NHTSA campaign number 23V-630. Additionally, the NHTSA has designated a specific campaign number for the fuel pump recall, which is 23E-068.

In summary, Hyundai is addressing a fuel pump problem in certain 2021-2022 Genesis vehicles to ensure the safety and reliability of these vehicles on the road. If you own one of these vehicles, it is important to receive the necessary replacement to avoid potential issues related to the fuel pump.

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.