Audi and Porsche recall 6,676 EVs in the US over battery fire risk

Audi and Porsche have initiated a recall affecting 6,676 of their electric vehicles (EVs) in the US. The recall stems from a potential fire risk linked to a battery sealing issue that could compromise vehicle safety.

The root of the issue lies in the possibility of a battery leak that could lead to arcing and ultimately result in a thermal event, which as you can guess poses a fire risk. If the problem is present the fix won’t be cheap. Audi and Porsche dealerships will inspect each affected vehicle and, if necessary, replace the entire battery pack.

According to the NHTSA recall document, Porsche initially became aware of this issue in 2022 when reports surfaced concerning “reduced insulation values” in some Taycan batteries. Upon investigation, it was discovered that liquid intrusion into the battery was the primary cause. In response, Porsche introduced a Teroson sealant into battery production in September 2022, aiming to address the situation.

However, the problem persisted. In March, Porsche received reports of liquid intrusion issues in some vehicles outside the U.S. market, despite the Teroson sealant. Further investigation revealed that low resistance values and liquid ingress into the battery were still occurring. In May, Porsche adapted its production protocol to incorporate an enhanced Teroson sealant, but the issue persisted.

The NHTSA recall affects 4,777 Taycans from the 2023 model year, encompassing all body styles. Audi, on the other hand, is recalling 1,899 e-tron GT and RS e-tron GT models, all from the 2023 model year. Both automakers believe that only around three percent of the 6,676 vehicles (approximately 200 cars) are actually affected. There have been no reported incidents of fires, injuries, or fatalities related to this issue in the US market.

Transport Canada has not yet posted a similar recall notice.

Owners of the affected vehicles are encouraged to contact their local dealerships or the National Highway Traffic Safety Administration (NHTSA) to verify if their vehicle is included in the recall. The recall documents note that these vehicles are equipped with a built-in warning system that will display a yellow warning light on the dashboard if insulation resistance values drop, eventually turning to red if it drops further.

You can read the full recall notices below.