Mack Trucks Issues Recall for Electric Vehicles Due to Battery Defect Fire Risk

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Mack Trucks, Inc. has announced a recall affecting seven of its 2022-2024 LRBE electric vehicles due to a defect in battery packs that poses a fire risk. The National Highway Traffic Safety Administration (NHTSA) assigned the recall number 25V-185, with Mack identifying the issue under recall number SC0475. The vehicles in question were produced between May 13, 2021, and June 13, 2023, and contain BorgWarner Akasol Gen 3 batteries flagged as suspect due to manufacturing process irregularities.

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The defect stems from inadequately torqued hardware within the battery packs, which could loosen and fall inside, potentially causing short circuits. This situation increases the risk of thermal events and fire. The defect was identified after a January 6, 2025, incident in Egypt where a BorgWarner battery experienced thermal runaway while uninstalled. Subsequent investigations linked the issue to the BorgWarner facility in Hazel Park, Michigan, which supplied the batteries to Volvo Trucks North America and Nova Bus, and later impacted Mack vehicles in the U.S.

By February 3, 2025, Volvo’s Product Safety Committees in Europe and North America had determined the existence of a product safety defect, leading to Mack’s decision to initiate the recall. No injuries, accidents, or warranty claims have been reported in connection with this defect. Vehicles that may have the defective batteries will be recalled, and suspect battery packs will be replaced free of charge under Mack’s Manufacturer’s Reimbursement Plan on file with NHTSA.

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Dealer notifications for the recall are scheduled to begin on or before March 30, 2025, with owner letters expected to be mailed by May 19, 2025. Any vehicles under Mack’s control that contain suspect batteries will remain on hold until the issue is resolved. The replacement batteries will be sourced from BorgWarner with manufacturing process improvements to prevent recurrence of the defect.

Article by multiple RFHC contributors, based upon information from Mack Trucks, Inc. and NHTSA.

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