Battery Fire Risk Leads to Recall of Motiv Electric Buses — All 55 Vehicles Already Repaired

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Residents and transportation agencies using electric buses built by Motiv Power Systems should be aware that 55 battery-powered vehicles were affected by a recent recall due to a fire risk. While no school buses were involved, the affected vehicles — built on Ford F59 chassis and operating between 2021 and 2024 — were found to contain faulty battery packs that could pose safety hazards, including the potential for smoke, fire, or electrical shock.

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The issue was traced back to battery packs supplied by Our Next Energy (ONE), which reported that an unseated fastener along the battery’s center spline could allow foreign substances to enter the pack. This could lead to loss of electrical isolation or a high-voltage short circuit. The problem prompted ONE’s own recall (25E-022), with Motiv subsequently identifying that these components had been installed in all 55 of its affected vehicles. The recall was listed under NHTSA Recall No. 25V456.

Fortunately, Motiv has completed remedy actions on all impacted units, including both in-service vehicles and spare battery packs reserved for future production. Field service technicians handled the repairs during routine inspections, eliminating the need for customer notifications or dealer involvement.

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The fix involved visual inspections, vacuum leak tests, and serial number tracking. In cases where issues were detected, technicians performed isolation checks and additional tests, and in some cases returned the de-energized battery packs to ONE for further evaluation. Updated assembly protocols and stricter fastener installation verification have been put in place to prevent similar issues in future production. No public action is currently required, and no additional notifications are planned as all repairs are complete.

Article by multiple contributors, based upon information from a safety recall report issued by the National Highway Traffic Safety Administration (NHTSA) and Motiv Power Systems.

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