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NHTSA Battery-Related Recalls, Broad Failure Categories per Reported Defect & Cause - 2025 Per NHTSA recall descriptions, there were approximately 67 battery-related recalls (includes 12V SLI, HV or other battery) in 2025. Each was classified into one of eight defined broad failure categories.
Module/Pack-Level Defects led in recall frequency with 20 incidents. Cell-Level Defects, despite fewer recalls, affected the largest fleet. Electrical Interconnects & Protection and Controls/Software issues were significant contributors. Impact and frequency didn’t always align - categories with fewer recalls can still pose major risk due to large vehicle exposure.
Source: NHTSA Recalls by Manufacturer | Department of Transportation - Data Portal and Part 573 Safety Recall Reports
Extracted from the PDF; charts and images may read imperfectly.
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