Samsung SDI has initiated a recall of approximately 180,196 high-voltage battery packs installed in plug-in hybrid vehicles from Ford, FCA US (Jeep), and Audi. The recall addresses potential internal cell failures that could lead to a loss of drive power and an increased risk of fire.
Affected Vehicles and Battery Details
The recalled batteries were manufactured at various points between July 1, 2020, and March 28, 2023. They were supplied to:
- FCA US (Jeep): 155,096 vehicles (2020-2024 Wrangler and Grand Cherokee)
- Ford: 20,484 vehicles (2020-2024 Escape and 2021-2024 Lincoln Corsair)
- Audi: 4,616 vehicles (2022-2023 Q5 and 2022 A7)
Samsung SDI emphasizes that each battery was tailored to the specific specifications and requirements of each automaker. Therefore, they are referring to the automakers’ prior recalls for detailed remedy information.
Root Cause Investigations and Findings
The automakers had previously issued recalls for these battery issues in late 2023. While no injuries or accidents have been reported, investigations revealed:
- Ford: Suspects a manufacturing defect causing damage to the battery cell separator, potentially leading to internal short circuits. Ford customers will see a “stop safely now” message displayed in the instrument cluster in the event of a battery short.
- FCA US (Jeep): Also identifies potential separator damage but suggests that complex interactions within the cells could lead to fires in rare cases.
- Audi: Reports potential thermal overload within the battery cells, possibly resulting in smoke or fire. The automaker is aware of four “thermal events” in markets outside of the U.S.
Remedy and Software Updates
Ford, FCA US, and Audi are developing software updates to better detect battery abnormalities and alert drivers.
- Ford expects its update will be available in Q2.
- FCA US has begun notifying dealers about a pending software update.
- Audi’s update, also in Q2 2025, will detect potential issues and alert drivers.
- Audi will replace battery packs at no cost to customers who experience issues before the update is available. In these cases, customers will be directed to visit a dealer and instructed not to charge their vehicles from external sources or via the combustion engine until the affected modules or battery pack can be replaced.
Manufacturing and Inspection
Samsung SDI implemented an X-ray inspection system at its facilities in November 2021 to detect potential damage during the cell manufacturing process. However, due to the complex nature of battery cells, potentially defective batteries may have been installed in vehicles through August 2023.
Recall Chronology and Key Details
The recall follows a series of reported fire incidents and investigations by the automakers, beginning in May 2023. These investigations revealed that the following battery part numbers are affected:
- (FCA US) P05193152AC, P05193168AE~AL, P05193176AJ~AP, P05193177AJ~AP, P05193181AA,P05193182AA,P05193199AC,P05193200AC
- (AUDI) PA0180LS003E~H, PA0180LS003J, PA1904P105C, PA1904P106C
- (Ford) MP0217NS002A~E, MP0217NS002F~H, MV2003E101AS
Sources: NHTSA, Automotive Dive
