Hyundai and Kia Recall 14 U.S. EVs Over Fire Risk from Battery Defect

Hyundai Motor Co. and Kia Corp. have issued a recall for 14 electric vehicles (EVs) in the United States after identifying a manufacturing defect in battery cells that could lead to fires. The recall affects six Hyundai IONIQ 5 models (2023–2024), seven Kia EV6 models (2022–2024), and one Kia EV9 (2024), all equipped with battery modules supplied by SK On.

Defect Identified in Battery Modules

In a letter dated July 9, 2026, Hyundai notified the National Highway Traffic Safety Administration (NHTSA) that misaligned electrodes in certain battery cells could cause an internal short circuit. The defect, traced to a specific production period at SK On’s facilities, poses a fire risk, though Hyundai confirmed no incidents, crashes, or injuries have been reported in the U.S. as of the recall announcement.

Hyundai launched an investigation into the issue last month, determining that only a limited number of vehicles were affected. The automaker stated that the defective modules were installed in a small batch of EVs produced during the identified period. Owners of the recalled vehicles are urged to park outdoors and away from structures until repairs are completed. Hyundai also recommends limiting charging to 80% of battery capacity as a precautionary measure.

Repair Process and Owner Notifications

Hyundai and Kia will replace the battery system assembly (BSA) in all affected vehicles at no cost to owners, regardless of warranty status. Hyundai will begin mailing notification letters to owners on August 31, 2026, while Kia will send notifications for EV9 and EV6 models starting August 7, 2026. Owners can contact Hyundai’s customer service line at 855-371-9460 (recall number 305) or Kia’s hotline at 1-800-333-4542 (recall number SC375) for further assistance. The NHTSA has also provided a hotline (1-888-327-4236) and its website for additional recall information.

As of now, the recall is limited to the U.S. market. Hyundai has not announced any recalls in other regions, nor has it disclosed whether additional models may be affected.

Implications for EV Battery Safety

The recall highlights ongoing challenges in EV battery production, particularly as automakers ramp up manufacturing to meet growing demand. SK On, a key battery supplier for Hyundai and Kia, has not publicly commented on the defect or its role in the recall process. The misalignment of electrodes—a rare but critical flaw—underscores the importance of rigorous quality control in battery cell manufacturing.

For affected owners, the recall process is designed to be seamless. Authorized dealerships will replace the BSA free of charge, though the precautionary measures—such as parking outdoors and limiting charging—may pose temporary inconveniences. The NHTSA’s oversight ensures compliance with safety standards, while the limited scope of the recall suggests the issue was identified before widespread incidents occurred.

Hyundai and Kia have not indicated whether other models use the same battery modules from SK On or if further recalls are under consideration. The automakers continue to monitor the situation and will provide updates as necessary.

Hyundai and Kia Recall 14 EVs in U.S. Over Fire Risk Linked to Battery Cell Defect

Defect Identified in Battery Modules

Repair Process and Owner Notifications

Implications for EV Battery Safety

Comments