Volkswagen Group of America, Inc. has issued a recall for a limited number of 2023-2024 ID.4 electric vehicles (EVs) after finding a manufacturing defect in the high-voltage battery modules that poses a fire risk. The safety campaign, NHTSA Campaign 25V836, affects 311 units produced between September 16, 2022, and September 22, 2024.
The underlying issue is a production deviation at the cell supplier, SK Battery America Inc., based in Commerce, Georgia. An investigation, which included tear-down analysis and CT imaging, confirmed that certain individual battery cells within the high-voltage (HV) modules contain misaligned electrodes, specifically shifted cathodes. This misalignment can lead to an internal short circuit, which may result in a thermal event or fire while the vehicle is driving or charging.
The investigation was initiated after a thermal event involving an ID.4 using a Level 3 DC charger in January 2024. Subsequent incidents were reported in California, Utah, and Colorado between July 2024 and August 2025 under various conditions.
Due to the confirmed risk, Volkswagen has issued an urgent advisory to affected owners pending the repair:
- Parking Outdoors: Owners are advised to park their vehicles outdoors immediately after charging and should not leave them charging indoors overnight.
- Charging Limit: Drivers must set the high-voltage battery system to a maximum state of charge of 80%.
- Avoid DC Fast Charging: Owners are instructed to avoid using Level 3 DC chargers to mitigate thermal risks.
Dealers will replace the potentially affected HV battery cell modules at no cost to the owner.
Owner notification letters are expected to be mailed by January 30, 2026.
