Electric Vehicle Recall Guide: EV Battery & Safety Risks
Electric vehicles are transforming transportation in the United States, but with rapid growth comes new safety challenges. As EV adoption accelerates, so do electric vehicle recalls. In 2025 alone, the National Highway Traffic Safety Administration issued dozens of EV-related recalls affecting millions of vehicles from Tesla, Hyundai, Chevrolet, BMW, Ford, and other manufacturers. Whether you already own an electric vehicle or are considering one, understanding EV battery recalls, fire risks, and safety procedures is essential for protecting yourself and your family.
This guide covers why electric vehicles get recalled, the most significant EV recalls in recent years, what the NHTSA does to keep you safe, and exactly what steps to take if your EV is affected.
Why Electric Vehicles Get Recalled
Electric vehicles share some recall triggers with traditional cars, such as faulty airbags or defective brakes. However, EVs introduce unique risks tied to their battery systems, software architecture, and charging components. Understanding these risks helps you evaluate recall notices and respond appropriately.
Battery Thermal Runaway
The most serious EV-specific hazard is battery thermal runaway. Lithium-ion battery packs, which power virtually every modern electric vehicle, store enormous amounts of energy. If a cell within the pack is damaged, defective, or exposed to extreme conditions, it can overheat uncontrollably. This overheating can cascade from one cell to adjacent cells, producing intense heat, toxic gases, and in some cases, fire.
Thermal runaway can be triggered by manufacturing defects within individual battery cells, physical damage to the battery pack from road debris or collisions, internal short circuits caused by contaminants introduced during production, or prolonged exposure to extreme temperatures. Battery fires are difficult to extinguish because the cells generate their own oxygen as they decompose. Fire departments across the country have reported that EV battery fires can take hours to fully suppress and may reignite days after the initial event.
Several major EV battery recalls have been directly linked to thermal runaway risk, including large-scale campaigns by Hyundai, General Motors, and BMW.
Software and Firmware Defects
Modern electric vehicles are controlled by millions of lines of software code. This software manages everything from battery charging and thermal regulation to autonomous driving features, regenerative braking, and display systems. When software contains bugs, the consequences can range from minor annoyances to serious safety hazards.
Common software-related recall triggers include battery management system errors that allow overcharging or undercharging, miscalibrated power delivery that causes unintended acceleration or loss of power, autopilot and driver-assistance malfunctions that fail to detect obstacles, and dashboard display failures that prevent drivers from seeing critical warnings.
The advantage of software-related recalls is that many can be resolved through over-the-air updates. Tesla, in particular, has issued numerous recalls that were addressed by pushing a software patch to affected vehicles without requiring a dealership visit. However, an over-the-air fix is still classified as a recall by the NHTSA.
Charging System Failures
The charging system is another area where EVs face unique recall risks. Defective onboard chargers can overheat during charging sessions, creating fire hazards. Faulty charge port connectors may arc or melt. Coolant leaks within the battery thermal management system can compromise charging safety. Inadequate ground fault protection in charging hardware can create electrocution risks.
Charging-related recalls have affected both the vehicles themselves and third-party charging equipment. EV owners should pay attention to recalls covering home charging units (known as EVSEs) as well as their vehicle.
High-Voltage Component Hazards
Electric vehicles operate at voltages far higher than traditional 12-volt automotive systems. The high-voltage battery pack, electric motor, power inverter, and associated wiring all carry enough voltage to cause serious injury or death if insulation fails or connectors degrade. Recalls have been issued for corroded high-voltage connectors, improperly sealed battery enclosures that allow moisture intrusion, and wiring harness defects.
Major EV Recalls in Recent Years
The scale of electric vehicle recalls has grown significantly as the EV market has expanded. Here are some of the most notable campaigns.
Tesla Recalls
Tesla leads in total EV recall volume, partly because it sells the most electric vehicles in the United States and partly because the NHTSA classifies over-the-air software updates as formal recalls. In 2023 and 2024, Tesla issued recalls covering more than four million vehicles for Autopilot software that was insufficiently responsive to driver attention monitoring. Additional Tesla recalls have addressed suspension components, door latch assemblies, trunk lid openings, rearview camera failures, and power steering loss. While many of these were resolved via software updates, some required physical inspection or part replacement at a service center.
Hyundai and Kia Battery Recalls
Hyundai issued one of the most expensive EV recalls in history when it recalled approximately 82,000 Kona Electric vehicles worldwide due to the risk of battery cell short circuits that could cause fires. The recall, which involved replacing entire battery packs at a cost of roughly $900 million, highlighted the financial and safety stakes of EV battery defects. The root cause was traced to manufacturing defects at a battery cell supplier.
General Motors and the Chevrolet Bolt
General Motors recalled all Chevrolet Bolt EV and Bolt EUV vehicles produced between 2017 and 2022, totaling approximately 143,000 units, after multiple battery fires were reported. GM initially advised owners to limit charging to 90% capacity and avoid depleting the battery below 70 miles of range. Eventually, GM replaced the battery modules in all affected vehicles. The Bolt recall cost GM over $1.8 billion and temporarily halted production.
BMW and Ford EV Recalls
BMW recalled certain iX and i4 models for battery issues, while Ford issued recalls for the Mustang Mach-E related to overheating high-voltage battery contactors that could cause loss of propulsion. These recalls, while smaller in scope than the Bolt campaign, underscored that EV battery safety challenges are not limited to a single manufacturer.
Rivian, Lucid, and Other EV Startups
Newer EV manufacturers have also faced recalls. Rivian recalled R1T trucks and R1S SUVs for issues including loose fasteners, misaligned seat belt anchors, and airbag sensor errors. Lucid recalled Air sedans for wiring harness problems. As these companies scale production, their recall histories will continue to grow.
How NHTSA Oversees EV Safety Recalls
The National Highway Traffic Safety Administration is the federal agency responsible for vehicle safety in the United States. NHTSA plays a critical role in identifying, investigating, and enforcing EV recalls.
How NHTSA Identifies EV Safety Problems
NHTSA monitors vehicle safety through consumer complaint data submitted at NHTSA.gov, manufacturer-reported early warning data including fire and injury reports, field investigations triggered by patterns of complaints, and crash data from police reports and insurance records. When NHTSA identifies a potential defect, it opens an investigation, which can lead to a voluntary recall by the manufacturer or, in rare cases, a mandatory recall order.
Over-the-Air Updates and Recall Classification
One area of evolving policy is how NHTSA handles over-the-air software updates. The agency has made clear that a safety-related software fix delivered over the air is still a recall. This means that even if a Tesla owner receives a software update overnight that fixes a safety issue, it is officially recorded as a recall in NHTSA's database. This classification sometimes creates confusion because the word recall implies a physical return to a dealership, but the key point is that NHTSA tracks and enforces accountability regardless of the delivery method.
Checking Your Vehicle for Open Recalls
Every vehicle owner should periodically check for open recalls. Enter your Vehicle Identification Number at NHTSA.gov/recalls to see any active recalls for your specific vehicle. You can also search for EV recalls by make, model, and year on RecallPedia. For a detailed walkthrough of the recall checking process for any product you own, see our guide on how to check if a product is recalled.
What to Do If Your Electric Vehicle Is Recalled
Receiving a recall notice for your EV can be unsettling, but the process for responding is straightforward.
Read the Recall Notice Carefully
The notice will describe the specific defect, the risk it poses, and the remedy. Pay close attention to whether the recall requires a dealership visit, an over-the-air update, or simply a parts inspection. Some recalls include interim safety measures you should follow until the repair is completed.
Schedule the Repair Promptly
Recall repairs are free of charge by federal law. Contact your dealer or service center to schedule the work. If the recall involves a battery replacement, be aware that parts availability may cause delays. Ask the dealer for an estimated timeline.
Follow Interim Safety Instructions
Some EV battery recalls include temporary precautions while you wait for the repair. These may include parking outdoors and away from structures, limiting charging to 80% or 90% of capacity, avoiding letting the battery drain below a specified level, and not charging the vehicle overnight unattended. These precautions are not optional. They are issued because the manufacturer and NHTSA have determined that the fire risk is real and present before the repair is completed.
Keep Records
Document all communications with the dealer, the recall notice, and the completion of any repairs. This documentation protects you if the same issue recurs or if you sell the vehicle later.
Fire Safety Tips for EV Owners
While EV fires are statistically less common per vehicle mile than gasoline car fires, they present unique challenges when they do occur. Being prepared is important.
Charging Safety
Always use the manufacturer-provided charging equipment or a certified third-party EVSE. Avoid using damaged charging cables or adapters. Do not charge your EV using an extension cord unless the manufacturer explicitly approves it. Have a qualified electrician install your home charging station and ensure the circuit meets the required amperage.
Parking and Storage
If your EV is under an active battery-related recall, park it outdoors and away from buildings until the repair is complete. Even without an active recall, it is good practice to ensure your garage has a working smoke detector and that your EV is parked where firefighters can access it easily.
Recognizing Warning Signs
Be alert for unusual behavior that could indicate a battery problem. Warning signs include a sudden drop in range not explained by weather or driving conditions, unusual odors such as a sweet chemical smell or burning plastic, popping or hissing sounds coming from the battery area, visible swelling or deformation of the battery pack, and repeated charging errors or warnings on the dashboard. If you notice any of these signs, stop driving the vehicle, move away from it, and contact your dealer and emergency services if necessary.
What to Do in an EV Fire
If your electric vehicle catches fire, get all occupants out of the vehicle and move at least 100 feet away. Call 911 immediately and inform the dispatcher that an electric vehicle is involved, as EV fires require specialized suppression techniques. Do not attempt to extinguish a battery fire yourself. Lithium-ion battery fires can reignite and produce toxic fumes. After an EV fire, the vehicle should not be stored indoors or near structures, as thermal runaway can restart hours or even days later.
The Future of EV Recall Safety
As battery technology improves and manufacturing processes mature, the safety profile of electric vehicles is expected to improve. Solid-state batteries, which replace the liquid electrolyte in current lithium-ion cells with a solid material, promise to reduce thermal runaway risk significantly. Advances in battery management software, cell-level monitoring, and quality control during manufacturing are also reducing defect rates.
At the same time, NHTSA is expanding its EV-specific expertise, hiring engineers with battery technology backgrounds, and developing new testing protocols for high-voltage vehicle systems. Regulatory frameworks are evolving to address the unique challenges of software-defined vehicles, including clearer guidelines for over-the-air update accountability.
For consumers, the most important step remains the same: stay informed. Check for recalls regularly, respond to recall notices promptly, and follow all safety instructions from the manufacturer and NHTSA.
Key Resources for EV Owners
- RecallPedia - Search the recall database for your vehicle by make, model, or keyword
- NHTSA.gov/recalls - Enter your VIN to check for open recalls on any vehicle
- SaferCar app - NHTSA's mobile app sends real-time recall notifications for vehicles you register
- Your dealer or manufacturer - Contact them directly for recall repair scheduling and questions
Electric vehicles represent a major leap forward in automotive technology, but like any complex product, they are not immune to defects. EV battery recalls, software fixes, and charging system repairs are a normal part of the ownership experience. What matters most is your response. Stay aware of open recalls, act on them promptly, and follow fire safety best practices. A few minutes of attention can prevent a serious safety incident.
For real-time electric vehicle recall information, search RecallPedia or visit NHTSA.gov. If you are experiencing a vehicle emergency, call 911 immediately.