2025 Hyundai IONIQ 5: Loose Battery Connection Could Pose Fire Risk

Hyundai Motor Company has announced a safety defect affecting a small number of 2025 Hyundai IONIQ 5 electric vehicles due to a potentially loose high-voltage battery connection. While no incidents have been reported, the defect could increase the risk of an electrical fire or cause the vehicle to lose power unexpectedly.

What’s the Issue with the 2025 Hyundai IONIQ 5 electric vehicle?

The recall involves a bus bar within the high-voltage battery system that may have been improperly tightened during assembly. The bus bar retention bolts may gradually loosen over time, leading to:

• Electrical arcing inside the high-voltage battery pack.
• Increased fire risk.
• Voltage sensor errors that can cause the vehicle to enter “fail-safe” mode, reducing drivability.

Hyundai advises all affected owners to park their vehicles outside and away from buildings or structures until the recall repair is completed.

How Did This Happen?

The defect was traced to an assembly process error:

• The torque tool controller failed during production.
• The Programmable Logic Controller (PLC) did not confirm proper tightening of connections during the battery system assembly process.

Timeline of Events

• June 18, 2025 – During a routine inspection, the BSA Quality Assurance team discovered the defect. Interim measures were implemented, and an internal audit identified units with suspect torque tightening.
• July 10, 2025 – Hyundai Motor Group Manufacturing America (HMGMA) was informed that 11 units at supplier Mobis and 58 units already received by HMGMA had the defect. All identified units were retightened to specifications.
• July 11, 2025 – NASO began a U.S. market investigation to determine if affected vehicles had reached dealerships.
• July 16, 2025 – Hyundai’s North American Safety Decision Authority (NASDA) approved a safety recall of all affected 2025 IONIQ 5 vehicles in the U.S.

Vehicles Affected By The Battery Problem

The recall covers a small number of 2025 Hyundai IONIQ 5 units sold in the U.S. Hyundai has not received any crash, fire, or fatality reports related to this defect as of the recall announcement.

What Will Hyundai Do?

• Dealers will inspect the high-voltage battery system and re-tighten bus bar bolts to the correct torque specification if necessary.
• Owner notification letters are scheduled to be mailed September 20, 2025.
• Hyundai recall number: 280.
• NHTSA campaign number: 25V482.

If Your 2025 Hyundai IONIQ 5 Is Affected

1. Follow Hyundai’s safety advice – park outside, away from buildings or flammable structures, until the repair is complete.
2. Schedule an inspection with your local Hyundai dealer once you receive the recall notice.