Battery Cables Warning: Park Vehicles Outside

author: FutureCar Staff    

A risk of fire has been identified in more than 4,000 vehicles due to a loose battery cable in the 2023-2024 Alfa Romeo Tonale and Dodge Hornet PHEV models. The issue stems from incorrectly torqued nuts on cables connected to both the 12-volt and high-voltage batteries in the plug-in hybrid variants of these vehicles. This fire risk exists regardless of whether the vehicle is turned on or off. As a precaution, both manufacturers are advising owners to park their vehicles outdoors until a recall repair can be conducted.

In the United States, approximately 1,875 Alfa Romeo Tonales manufactured between February 9 and August 23, and 2,254 Dodge Hornets produced between December 13, 2022, and August 23, 2023, may be affected by this problem. In total, 4,129 vehicles in the United States could potentially be impacted.

Stellantis, the parent company of both Alfa Romeo and Dodge, initiated an investigation into this issue in August. The investigation was prompted by a report from an assembly line worker at the Pomigliano Plant in Italy, who discovered the concern while checking the torque of nuts connecting the battery cables to the integrated dual charging module.

The Customer Experience team at Stellantis reviewed production data and torque traceability data, and consulted with engineering to understand the design and history of the part. It was determined that the nuts had been improperly tightened due to the use of wireless screwdrivers by workers.

To address this issue, the plant issued a corrective update to the screwdrivers on August 24, ensuring that the nuts would be properly tightened. Additionally, results tracking was implemented in the manufacturing execution system to improve accountability.

While these measures resolved the problem for units built after August 24, all Tonales and Hornets manufactured prior to that date will need to be recalled to prevent the risk of fire. Stellantis will begin contacting customers on October 27 to request the return of their vehicles to a nearby dealership for a comprehensive inspection by a qualified mechanic. During this inspection, the integrated dual charging module will be thoroughly examined, and if necessary, the nuts will be correctly torqued or replaced if completely detached.

As of now, Stellantis is not aware of any injuries or deaths resulting from this issue. However, the company has received two field reports of problems potentially related to the loose battery cable. To minimize the risk of fire spreading to buildings, Stellantis recommends that owners of 2023-2024 Alfa Romeo Tonale and Dodge Hornet PHEVs park their vehicles outside until the recall repair has been completed.

FutureCar Staff