Honda CR-V Hybrids May Have Battery Fault That Could Cause Fire Or Total Breakdown

A potential fire risk has been identified in the lithium-ion battery packs of certain previous generation Honda CR-V Hybrid models, according to a recall notice recently published by the National Highway Traffic Safety Administration (NHTSA).

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The issue, Honda explains, stems from variations in the manufacturing process. Specifically, some of the negative terminals inside the battery pack have been produced with insufficient copper cladding residual thickness. This manufacturing defect could lead to fractured cladding, which might expose the underlying aluminum. When aluminum interacts with the battery’s electrolyte, it can form an alloy that compromises the integrity of the battery cell. In the worst-case scenario, this could cause the terminal or busbar within the battery to fail.

Read: 2025 Honda CR-V e:FCEV Is A Plug-in Hybrid, But With Hydrogen

Should such a failure occur, owners would be left stranded, unable to drive their CR-V Hybrid. If the break happens while the battery is energized, there’s a chance of sparking, which raises the risk of fire, crash, or injury, according to Honda. The lithium-ion battery in question was supplied by Panasonic, a major player in the battery industry.

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In total, 98 examples of the 2023 Honda CR-V Hybrid are being recalled. These vehicles were produced between October 6, 2022, and January 24, 2023.

Panasonic alerted Honda to an issue in mid-January 2023 when it found a battery cell leak during an inspection. In June, the Japanese carmaker conducted an initial evaluation of the fault but found there was no concern of ignition by sparks from switches, gas poisoning, or electric shock. Earlier this year, Panasonic told Honda the terminal could rupture and that a leak might cause the busbar to disconnect. Honda continued to investigate the issue and concluded in September there was a defect and that a recall would be required.

Owners of the affected CR-V Hybrids will be notified of the recall starting November 27. Honda has instructed its dealerships to replace the faulty battery modules with new ones to resolve the issue and eliminate any risk.

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