Hyundai recalls IONIQ 5 and IONIQ 9 electric vehicles over battery safety issue

Hyundai Motor America has issued a recall for 27 of its 2025-2026 model year IONIQ 5 and IONIQ 9 electric vehicles in the United States, as reported by 32CARS. The affected vehicles were manufactured at the Hyundai Motor Group Metaplant America (HMGMA) facility in Georgia.

The recall stems from a potential assembly error in the high-voltage battery system. In some units, the bolts securing the power busbars may not have been tightened to the proper torque specification. Over time, these connections could loosen, creating a risk of electrical arcing within the battery module.

This electrical sparking increases the likelihood of a fire. Furthermore, an unstable connection could trigger voltage sensor errors, forcing the vehicle into a reduced-power limp mode that severely hampers performance. Hyundai officially states that no accidents, injuries, or fires related to this defect have been reported.

An internal investigation suggests the issue may have occurred during the rework of battery assemblies on the production line. In isolated cases, the automated torque monitoring system could have been bypassed when a unit was returned to the assembly process after adjustments. Once identified in November 2025, the manufacturing procedures were corrected.

Hyundai has also implemented a stop-sale order on the affected vehicles, prohibiting dealers from selling any new units with an open recall until repairs are completed. At the time of reporting, a permanent fix is still under development. Owners are advised to contact their dealer for an inspection.

Once the remedy is available, dealers will inspect the battery assembly free of charge and tighten any fasteners as needed. Owner notifications are scheduled for April 2026, and the relevant VIN numbers are already available for verification.