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Audi has issued a recall for certain 2023 Audi Q5 vehicles due to a defect in high-voltage battery modules that could lead to thermal overload, posing a fire risk. The recall, identified as NHTSA Recall No. 25V-080, affects approximately 2,616 vehicles produced between November 10, 2022, and August 8, 2023. The issue stems from potential manufacturing deviations in the battery cells, which may cause micro-defects leading to overheating.
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The defective battery modules were supplied by Samsung SDI and were found to have possible separator damage, which can cause localized stress in the battery cells. Audi and its supplier conducted extensive analysis but were unable to pinpoint a single root cause. The supplier implemented process improvements in March 2023 to enhance the robustness of the battery cells. However, vehicles assembled before this date remain at risk and are included in the recall.
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As a remedy, Audi plans to introduce an advanced onboard diagnostic software that will detect battery performance issues and warn drivers before problems occur. The software is expected to be available in the second quarter of 2025. Until then, Audi is advising affected customers not to charge their vehicles from external sources. Customers with online-connected vehicles may receive interim solutions, such as module or battery replacement if critical issues are detected. Audi will also offer a reimbursement plan for those outside of warranty coverage.
Audi will notify dealers by February 14, 2025, and owners by April 11, 2025. So far, no injuries, crashes, or fires have been reported in the U.S. due to this defect.
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