Volkswagen Recalls Top-Selling U.S. BEV Over Battery Fault

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Volkswagen is set to recall 44,551 units of its best-selling electric vehicle, the ID.4, in the United States due to potential safety concerns involving the high-voltage battery systems. The recall follows a recent notice from the National Highway Traffic Safety Administration. All affected batteries feature defective cell modules supplied by a major South Korean battery manufacturer.

The issue originates from a manufacturing flaw in the high-voltage battery cell modules produced during a specific timeframe. In certain cases, misaligned electrodes can occur, which may increase the risk of battery fires.

To mitigate risks, Volkswagen recommends owners limit charging to 80 percent, avoid quick DC fast charging, and park their vehicles outdoors after charging. The company plans to replace the faulty battery modules at no cost to owners. The recall will be carried out in two separate phases.

The misalignment, known as “electrode misplacement,” involves the battery deforming and causing the positive and negative electrodes to shift out of alignment, according to industry experts. A clear sign of this defect is a bulging battery—a critical issue in battery manufacturing quality control.

The South Korean firm involved is among the top three battery producers in the country. It ranked sixth globally in installed battery capacity during the first ten months of last year, based on data from SNE Research. Other top-ten battery makers include six Chinese companies, two South Korean firms, and one Japanese company.

The ID.4 remains a flagship model for VW’s electric vehicle lineup worldwide. Last year, global sales of the ID.4 increased by 26.8 percent year-over-year, reaching approximately 163,400 units, making it Volkswagen’s leading electric model.

In China, the ID.4 is primarily manufactured and sold through two joint ventures. Cumulative sales in 2024 are estimated at around 72,000 and 34,000 units, respectively. VW has not announced a recall for the Chinese market at this time.