Honda CR-V hybrid may have battery failure that could cause

Panasonic is supplier of lithium-ion batteries that could catch fire

A recent recall notice issued by the National Highway Traffic Safety Administration (NHTSA) revealed a potential fire risk in the lithium-ion battery packs of certain previous-generation Honda CR-V hybrid models.

Honda explained that the issue stems from changes in the manufacturing process. Specifically, some negative terminals inside the battery pack were produced with insufficient remaining thickness of the copper layer. This manufacturing flaw can cause the cladding to crack, potentially exposing the underlying aluminum. When aluminum interacts with the battery electrolyte, it forms an alloy that compromises the integrity of the battery. In the worst case, this could cause terminals or busbars within the battery to fail.

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If such a malfunction occurs, owners will be stranded and unable to drive their CR-V Hybrid. Honda said if the battery breaks while power is applied, there is the potential for sparks to occur, increasing the risk of fire, crash or injury. The lithium-ion batteries involved were supplied by Panasonic, a major manufacturer in the battery industry.

A total of 98 2023 Honda CR-V Hybrids are recalled. The vehicles were produced between October 6, 2022 and January 24, 2023.

Panasonic alerted Honda to a problem in mid-January 2023, when it discovered a battery leak during an inspection. In June, the Japanese automaker conducted an initial assessment of the fault but found there were no problems with switch sparking, gas poisoning or electric shock. Earlier this year, Panasonic told Honda that terminals could crack and leaks could cause the busbars to disconnect. Honda continued to investigate the issue and concluded in September that a defect existed that warranted a recall.

Owners of affected CR-V hybrid vehicles will receive recall notices starting November 27. Honda has instructed its dealers to replace the faulty battery modules with new ones to fix the problem and eliminate any risk.