Chrysler Pacifica PHEV Fire Warning

On 2024-07-28 09:48:23

Chrysler (FCA US, LLC) has identified an issue affecting certain 2019-2021 Pacifica Plug-In Hybrid Electric (PHEV) vehicles, as well as some 2017-2018 Pacifica PHEVs that received a software update under an earlier recall (NHTSA recall number 22V-077). The problem lies with the battery pack, which poses a fire risk even when the vehicle is parked and the ignition is off.

 

Chrysler first became aware of this issue in February 2022 through the Vehicle Regulations Committee, prompting them to initiate a voluntary safety recall for specific Pacifica PHEVs, designated as recall Z11.

Since then, Chrysler has been collaborating with LG Energy Solution (LGES) to determine the cause of the problem. Their efforts included analyzing field reports, repurchasing vehicles, examining vehicle data, conducting thermal tests, and disassembling battery packs.

 

In November 2022, Chrysler's Technical Safety and Regulatory Compliance (TSRC) team was notified of a battery fire in a Pacifica PHEV that had already undergone the Z11 recall fix.

Between June 2023 and December 2023, TSRC became aware of five more fires involving the high-voltage (HV) battery in Pacifica PHEVs that had received the Z11 remedy. They attempted to repurchase these vehicles to assess the effectiveness of the recall fix.

In April 2024, Chrysler received a Pacifica PHEV with a post-Z11 remedy fire in the battery pack. After examining the vehicle and battery pack, they sent the battery back to the supplier for further inspection. They discovered a torn anode tab in one of the cells but could not identify a secondary factor causing the fires. This confirmed that the Z11 remedy was not effective.

A folded or torn anode tab can lead to lithium by-product build-up over time. This defect, coupled with another unidentified factor, can cause an internal short in the battery pack, potentially resulting in a vehicle fire.

 

Chrysler advises owners not to charge their vehicles and to park them outside and away from structures until repairs are made. Dealers will update the high-voltage battery pack control module (BPCM) software, and if necessary, replace the battery pack assembly. The recall numbers are 72B and 73B, and the NHTSA campaign numbers are 24V-356 and 24V-358. Vehicles previously repaired under recall 22V-077 will need to have the new fix applied.