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Dive Brief:

• Stellantis subsidiary FCA US has recalled 2020-2024 Jeep Wrangler and 2022-2024 Cherokee plug-in hybrid models for a defect in the high-voltage battery pack, which can lead to a fire while parked or driving, according to the National Highway Traffic Safety Administration.

• The recall potentially includes up to 154,032 hybrid Jeep vehicles produced between July 1, 2020, and Nov. 16, 2023, that are equipped with battery cells susceptible to separator damage. 

• Out of an abundance of caution, the company is advising owners of these models to park away from structures or other vehicles until the repairs are completed. Owners are also being advised to refrain from recharging the vehicle’s battery. Notification letters are expected to be mailed Oct. 17.

Dive Insight:

FCA US learned of the battery problem last year. On May 12, 2023, the company’s technical safety and regulatory compliance organization opened an investigation after receiving two field reports of fires originating from the high-voltage batteries in the 2021 Jeep Wrangler plug-in hybrid. The battery pack was supplied by Samsung SDI. 

After being notified of the fires, the automaker requested buybacks of both vehicles to conduct further analysis. From May through September 2023, FCA US received five additional reports of battery fires in 2021 and 2022 hybrid Wranglers. 

In October 2023, FCA US received two of the buyback vehicles and disassembled the battery packs for further inspection. Following the teardown, the automaker announced a recall in November 2023 for over 32,000 hybrid Jeep models to perform a software update for the battery pack control module, as well as replace the battery if a diagnostic fault code related to the condition was stored.

But in April through July of this year, FCA US received additional reports of battery pack fires in Wrangler and Grand Cherokee plug-in hybrids that already received the software update in the original recall. 

FCA US then launched an internal investigation with its supplier Samsung SDI on June 25, 2024, which included a more thorough analysis of the battery pack to determine the root cause of the problem.

In August, Samsung SDI notified FCA US that the fires likely were caused by battery cell separator damage combined with “other complex interactions within the cell,” according to the NHTSA report. The 2021 hybrid Wrangler is equipped with a 17 kilowatt-hour battery pack containing 96 individual cells.