BMW Recalls 136 EVs Over Battery Frame Safety Concerns

The familiar chime of a BMW notification takes on urgent meaning for 136 electric vehicle owners across America today. Following last month’s software-related recall affecting 70,000 EVs, BMW has issued another critical safety notice—this time targeting battery modules that could catastrophically fail after repeated charging cycles.

BMW’s Latest EV Recall: What Owners Need to Know

The recall centers on battery cell modules assembled with excessive compression force. According to BMW’s July 29, 2025 filing with the National Highway Traffic Safety Administration (NHTSA Report ID: 25V-579), this manufacturing flaw may cause module frames to weaken over time. Unlike typical recalls where only a fraction of vehicles exhibit defects, BMW confirms all 136 affected EVs contain these potentially compromised batteries.

Automotive safety experts warn the consequences could be severe. When battery module frames degrade, you risk sudden high-voltage system shutdowns while driving,” explains Dr. Elena Rodriguez, EV battery researcher at MIT’s Electrochemical Energy Lab (2024 study). “This isn’t just about stranded drivers—thermal runaway in lithium-ion batteries can lead to fires.” BMW’s internal testing suggests failures might not occur until late 2026, but proactive action is being taken now.

The Battery Assembly Flaw Explained

During production, individual battery cells are compressed into modules using precise pressure specifications. In these recalled vehicles, the force applied exceeded engineering thresholds by up to 15%. This creates microscopic stress points that worsen with each charge cycle. BMW’s technical bulletin notes: “Repeated expansion/contraction during charging gradually fatigues the frame.”

The defect traces back to a calibration error at BMW’s Dingolfing battery plant between November 2021 and February 2024. While no fires or crashes have been reported, BMW’s decision follows similar battery recalls by Hyundai (2023) and Ford (2024), highlighting industry-wide quality control challenges.

Affected Models and Repair Protocol

Dealers will replace entire battery modules—not full packs—in these models:

• 2022-2025 BMW iX (built Nov 3, 2021 – Feb 14, 2024)
• 2023-2024 BMW i7 (built June 12 – July 19, 2023)
• 2022-2023 BMW i4 (built June 2, 2022 – May 11, 2023)

Owners will receive mailed notifications starting September 5. Repairs require specialized equipment and take approximately 9 hours per vehicle. BMW advises: “Continue driving your EV, but avoid DC fast-charging until inspection.” All costs will be covered under BMW’s recall warranty (Reference: BMW Service Action 65 30 24).

BMW’s back-to-back recalls signal growing pains in the EV transition, but proactive battery replacements demonstrate crucial safety prioritization. If you own an iX, i7, or i4, verify your VIN at NHTSA.gov/recalls and schedule immediate inspection at your dealership.

Must Know

Q: How dangerous is this BMW battery defect?
A: While no incidents are reported, NHTSA classifies it as high-risk. Potential outcomes include sudden power loss at highway speeds or battery fires. BMW urges prompt repairs despite failures possibly developing later.

Q: Can I keep driving my recalled BMW EV?
A: Yes, but avoid DC fast-charging stations. Use Level 1/2 home charging only. Schedule dealer diagnostics immediately upon receiving your September notification.

Q: Which BMW EVs are NOT affected?
A: Current i5 sedans, iX3 SUVs, and all plug-in hybrids (PHEVs) use different battery assemblies and are excluded. Only specific iX, i7, and i4 models are involved.

Q: How long will battery module replacements take?
A: Approximately 9 hours per vehicle. Dealers will provide loaner cars. BMW covers all costs including diagnostics, parts, labor, and battery recalibration.