In an abundance of caution, Hyundai has advised a small number of Ioniq 5 EV owners to park their vehicles outside and away from homes or other potential flammable items because of a risk of a battery-pack fire. It’s the latest in a series of recalls involving the all-electric crossover this year. More from Headlight.News.
The problem involves a potential manufacturing defect in the battery pack.
Hyundai is warning a small number of Ioniq 5 owners that there may have been a problem on the assembly line impacting their vehicles’ battery pack, a defect that could result in a fire.
The National Highway Traffic Safety Administration, in turn, has advised owners “to park their vehicles outside and away from structures until the recall remedy is complete.” Hyundai dealers are being set up to inspect the high-voltage battery system on those vehicles and will make repairs, if necessary.
This is the latest in a series of recalls the Korean carmaker has launched for the Ioniq 5 this year.
What’s wrong
The 2025 Hyundai Ioniq 5 now can charge at Tesla Superchargers.
The issue concerns a metal strip called a busbar connecting the individual cells in th Ioniq 5’s high-voltage battery pack.
Hyundai advised NHTSA that a tool on the Battery System Assembly line may have failed and didn’t properly torque the bar in place. The automaker quickly caught the problem during a routine audit but says some potentially faulty packs may have made it onto the Ioniq 5 assembly lines before then.
All told, about 10 of the EVs may be equipped with those packs and will need to be inspected, according to the documentation filed with NHTSA.
What next
The NHTSA recall notification,
There have been no reports of fires or other problems involving those Ioniq 5 EVs, but the concern is that the bussbars could continue to loosen and cause a fire later on.
The problem is not just that the batteries could short out but that fires involving lithium-ion chemistry is especially difficult to bring under control.
As a result, Hyundai and NHTSA want owners of the affected vehicles to park their vehicles for the time being and keep them away from homes or other surroundings that could also go up in flames.
The automaker plans to have owners bring the EVs in for inspection and, if necessary, dealer service techs will properly tighten the bars down. Inspection and repairs, if necessary, will be made at no cost to owners.
More Recall News
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- Yet Another Tesla Cybertruck Recall
- GM Recalls 700k Pickups, SUVs for Faulty Engines
A string of recalls
The 2025 Hyundai Ioniq 5 added a Tesla-style NACS charger port.
The Hyundai Ioniq 5 has been one of the more successful non-Tesla EVs since it went on sale for the 2022 model year. The automaker sold 19,092 of them in the U.S. during the first half of 2025, a 2% year-over-year increase.
But the Ioniq 5 has had its troubles of late. It now has been recalled five separate times in 2025, more than during any other year.
The latest issues include two separate recalls for brake performance; one involving faulty rear airbags and another for headlight problems.
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