Jeep Grand Cherokee and Wrangler 4xe Models Subject to Recall Over Fire Risk

Chrysler (FCA US, LLC) is initiating a voluntary safety recall affecting over 112,000 plug-in hybrid Jeep Grand Cherokee and Wrangler models due to a defect that could lead to engine failure and a potential fire hazard, according to a report submitted to the National Highway Traffic Safety Administration (NHTSA). The issue stems from sand contamination within the engine block during the casting process, which can compromise internal engine components.

The recall encompasses 36,840 units of the 2023-2025 Jeep Grand Cherokee 4xe, with production dates ranging from July 19, 2023, to March 3, 2025. Additionally, 76,019 units of the 2024-2025 Jeep Wrangler 4xe, manufactured between June 7, 2023, and March 4, 2025, are included in this safety campaign. Both vehicle models are plug-in hybrids.

The presence of sand within the engine block can lead to catastrophic engine failure. This failure presents a dual risk: an unexpected and unrecoverable loss of propulsion, which could result in a vehicle crash without warning, and an increased risk of vehicle fires. Vehicle fires can pose a significant danger to occupants and those outside the vehicle, as well as cause property damage. Owners may notice preliminary warning signs such as a knocking noise emanating from the engine compartment or a malfunction indicator lamp illuminating before a complete engine failure occurs.

The issue was identified when Chrysler US LLC’s Technical Safety and Regulatory Compliance organization began an investigation in May 2025 following an uptick in engine compartment fires and loss of propulsion incidents reported in certain Jeep Wrangler and Grand Cherokee plug-in hybrid models. Through an analysis of warranty claims, repair orders, and field incidents between May and August 2025, the company determined the root cause to be sand contamination within the engine block. Engine teardowns confirmed the presence of sand, and manufacturing records pointed to a period between June 2023 and March 2024 at the engine block supplier, Nemak, where engines were not adequately cleaned after casting.

As of October 20, 2025, Chrysler US is aware of 36 customer assistance records, 144 warranty claims, 36 fires, and 50 reports of loss of propulsion potentially linked to this defect. The company has also noted 50 other service records related to the issue. While no accidents have been reported, there are three reported injuries associated with this defect.

The remedy for this recall is currently under development, and the specific repair procedure will differ from the recalled component. Chrysler US will notify dealers on or about November 13, 2025, and owners will begin receiving notifications on or about December 29, 2025. Owners will be able to check if their vehicle is included in the recall by VIN on November 13, 2025. The company advises owners of affected vehicles not to drive them and to park them outside due to the fire risk until the remedy is available.

Article by Mel Anara, based upon information from Chrysler (FCA US, LLC)

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