Kia Motors is recalling 2,209 Niro EVs from the 2022 model year due to potential safety issues with the high voltage battery safety plug. The plug has been found to overheat and melt, which could lead to a fire or a loss of power while driving.
According to the Safety Recall Report, the contact surfaces of the high voltage battery safety plug may develop high electrical resistance over time. While the exact cause is not yet determined, Kia believes the issue is related to a supplier deviation in the manufacturing of the Female-Female terminal.
The automaker first became aware of a potential problem in July 2023 when a report was received of a Niro EV shutting off while driving, with the dealer finding the safety plug had been melting. Although initially thought to be an isolated incident, Kia continued to investigate and discovered similar incidents, including one in Portugal.
In February 2024, Kia North America received a report about a Niro EV that wouldn’t start, leading to the discovery of melting on the safety plug. Subsequently, two more vehicles with melting safety plugs were discovered in March and April.
While no injuries, crashes, fatalities, or fires have been reported, Kia is taking precautionary measures. Owners are advised not to charge their vehicles in a garage or any other covered structure until the recall repair is completed.
The recall repair will involve dealers replacing the safety plug with a new one that has a solid bus bar connection with no Female-Female terminal. Owners of affected vehicles will be notified by mail with instructions on how to proceed.
