Dive Brief:
- Volkswagen Group of America has recalled nearly 14,000 electric ID.4 SUVs and Audi e-tron and Sportback models for an issue with the battery, which can lead to a loss of drive power, according to the National Highway Traffic Safety Administration.
- The battery charging problem is due to the presence of condensation on the printed circuit board of the EV’s integrated DC/DC-converter (OCDC) which may lead to a short, according to the NHTSA recall report.
- The recall covers certain 2024-2025 Audi Q4 E-Tron SUVs and Sportback models, and 2024 VW ID.4 vehicles. An estimated 10% are believed to have the defect. VW will replace the OCDC units free of charge. Owners notification letters will be sent on or before April 25.
Dive Insight:
According to the NHTSA recall report, drivers will receive several messages via the instrument cluster along with audible warnings alerting them of possible reduced driving functions if the no-charge condition occurs. However, if these messages are ignored and the vehicle is driven until the battery is discharged, drivers may experience a loss of “electronically controlled or assisted vehicle functions,” which may increase the risk of a crash.
VW discovered the problem in September 2024 after receiving field claims of vehicles not properly charging and reports of vehicles being towed-in to dealers. From October 2024 through January 2025, the automaker identified 344 field claims in the U.S. for VW and Audi EVs believed to be related to the issue.
VW engineers also evaluated the impact that varying temperatures and humidity could have on the OCDC. Its testing confirmed that the presence of condensation could lead to a gradual deactivation of vehicle electrical systems. As a result of its findings, the product safety committees of VW and Audi elected to recall the affected vehicles on Feb 21.
The electrical problems are a result of insufficient coating that protects the PCB from moisture, according to the NHTSA. The defective OCDC units were manufactured by supplier Bosch.
The remedy included adding additional coating to the unit’s PCB to better protect the electronics from moisture. A revised OCDC was introduced into production in June 2024 for Audi models and in September 2024 for the VW ID.4.
The recall of the ID.4 and Audi e-trons follows another VW recall in February for up to 177,493, model year 2024-2025 Atlas and Atlas Cross Sport SUVf for a loose engine cover that could melt from heat due to improper installation after servicing. The automaker revised the cover to prevent it from becoming loose and it was introduced in series production on Dec. 4, 2024.
