High Voltage Battery May Catch Fire

Affected vehicles (2)

Component / system

Defect

Hyundai Motor America (Hyundai) is recalling certain 2025-2026 IONIQ 5 and 2026 IONIQ 9 vehicles. The high voltage battery system may contain an improperly tightened bus bar, which can cause a short-circuit.

Risk / consequence

An electrical short in the high voltage battery system increases the risk of a fire.

Remedy

Dealers will inspect and tighten the bus bar retention bolts and replace the battery system assembly, as necessary, free of charge. Owner notification letters were mailed April 3, 2026. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 294. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on February 7, 2026.

Chronology of events

1. Nov 18, 2025

   On November 18, 2025, HMGMA notified NASO of a potential condition involving high voltage busbar bolts within certain BSA units supplied by MNAe. According to the supplier, the issue was identified after a BSA unit failed an automated quality test during production, prompting further inspection which identified potentially under torqued busbar bolts. Following notification, NASO initiated information gathering to understand the scope of the condition, the affected production processes, and potential flow out to the U.S. market. December 2025

2. Dec 18, 2025

   On December 18, 2025, HMGMA provided NASO with a list of potentially affected VINs. NASO continued its investigation in coordination with HMC and MNAe. During this period, NASO requested and reviewed additional information regarding the BSA manufacturing process, torque application at the relevant assembly stations, process data, rework flow procedures, and quality inspection practices. MNAe’s report confirmed that the issue could occur when BSAs were removed from the assembly line for rework and were subsequently reintroduced at a later stage allowing certain torque confirmation processes to be bypassed. MNAe further identified that the affected condition was limited to specific BSAs produced on one assembly line.

3. Jan 29, 2026

   January 29, 2026 NASO reviewed the supplier’s technical findings, traceability and test results and convened its North America Safety Decision Authority (“NASDA”), deciding to conduct a safety recall of the affected model year 2025–2026 Hyundai IONIQ 5 and 2026 IONIQ 9 vehicles in the U.S. market. As of the date of this filing, Hyundai has not received any reports of field incidents, crashes, injuries, fatalities, or fires related to the condition in the affected vehicles.

Notification schedule

Dealer notification

Apr 06, 2026 - Apr 06, 2026 No Dealers

Owner notification

Apr 06, 2026 - Apr 06, 2026 Phased Recall