Hyundai Recalls 2025 IONIQ 5 Over Potential Fire Risk and Drivability Issues

A recall issued by Hyundai Motor America could impact owners of certain 2025 Hyundai IONIQ 5 vehicles, prompting advisories to park outside due to a fire risk linked to improperly tightened bolts in the high-voltage battery system. Per a report filed with the National Highway Traffic Safety Administration (NHTSA), ten U.S.-market electric vehicles built between June 12 and June 13, 2025, at Hyundai’s Metaplant in Georgia are potentially affected. While no incidents or injuries have been reported, owners are being urged to act promptly once notifications begin in September.

The safety concern stems from a defect discovered in the Battery System Assembly (BSA), where retention bolts for the high-voltage bus bar may not have been adequately tightened during production. Over time, this issue could lead to the bolts loosening, creating the risk of electrical arcing within the battery pack. This in turn could result in an electrical fire or trigger a vehicle’s fail-safe mode, causing reduced drivability. The fault was traced to a malfunction in the torque tool controller, which failed to properly verify tightened connections during assembly.

In response, Hyundai initiated an internal audit and corrective measures at the supplier level in June 2025. By mid-July, 69 units with the defect had been identified and corrected, though Hyundai opted for a broader safety recall following a review by its North American Safety Decision Authority. Hyundai is advising owners not to park the affected vehicles inside garages or near structures until inspections and potential repairs are completed.

Remedies will be provided at no cost to vehicle owners. Hyundai will begin notifying dealers and owners on September 20, 2025, and affected vehicles will be inspected at authorized dealerships to determine if re-tightening of the bolts is necessary. Additionally, Hyundai will reimburse any out-of-pocket expenses related to addressing this recall, regardless of the vehicle’s warranty status. Vehicle owners can begin checking their VINs for recall status as early as July 25, 2025.

Article by multiple contributors, based upon information from Hyundai Motor America and the National Highway Traffic Safety Administration (NHTSA) press release.

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