Hyundai Motor has issued a safety advisory for a limited number of 2025 model year Ioniq 5 electric vehicles (EVs) in the United States due to a battery-related defect that could increase the risk of fire.
The automaker identified an issue involving improperly tightened bus bars—metal connectors used to distribute electrical current within the battery pack. According to Hyundai, a malfunction in a torque tool controller at the Battery System Assembly (BSA) supplier led to some bus bar bolts not being secured to required specifications. The issue was discovered during routine battery inspections.
Although the recall affects only 10 vehicles, Hyundai is urging those owners to avoid parking near structures or other vehicles until the problem is resolved. The company says the defect could cause the bus bar retaining bolts to loosen over time, potentially leading to electrical arcing within the battery pack. This could result in a fire or cause the vehicle to enter a reduced-power “limp mode” due to voltage sensing errors.
No incidents, injuries, or fires have been reported so far. Hyundai has stated that owners can continue driving their vehicles but should exercise caution when selecting parking locations until the repair is completed.
The affected vehicles will require a visit to a Hyundai dealership, where technicians will inspect and tighten the bus bar bolts to meet safety specifications. The automaker has not provided a timeline for when repairs will be completed but says owners will be notified directly.