BMW Recalls Over 130 Electric Vehicles Due to Battery Safety Risk

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BMW recalls 136 EVs over battery assembly defect that could lead to system shutdown or fire

BMW of North America is recalling 136 electric vehicles across three model lines after determining their high-voltage battery modules may not have been assembled to proper specifications, posing a potential safety risk. According to a safety recall report submitted to the National Highway Traffic Safety Administration (NHTSA), affected vehicles include the 2022–2025 BMW iX, 2023–2024 BMW i7, and 2022–2023 BMW i4 models. All recalled vehicles are powered by electric battery systems.

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The defect stems from excess force potentially used during the battery module assembly process. If the force exceeded specified limits or if other assembly aspects deviated from standards, the modules may face long-term stress. Over time, this stress could cause the battery frame to fail, particularly with repeated charging. A failed frame could lead to a shutdown of the vehicle’s high-voltage system, resulting in loss of propulsion. In rare cases, it may also increase the likelihood of a thermal event, both of which heighten crash or injury risk.

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BMW’s recall affects roughly 130 BMW iX SUVs, four BMW i7 sedans, and two BMW i4 sedans. Though no accidents, injuries, or thermal incidents have been reported, the manufacturer opted to initiate the recall on July 9, 2025, as a precaution. Owners will be notified by mail starting September 5, 2025. BMW dealerships will replace the affected battery modules at no cost to the customer. Until repairs are completed, consumers are advised not to drive the vehicles and to park them outside.

The high-voltage battery modules identified in the recall are associated with part numbers 8886723, 8863438, 8886695, 8886696, and 8865398. Vehicle owners will be able to check their vehicle’s recall status via VIN search beginning the same day notifications are mailed.

Article by multiple contributors, based upon information from a press release by the National Highway Traffic Safety Administration and BMW of North America.

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