Loose Battery Cables Pose Fire Risk for Alfa Romeo Tonale and Dodge Hornet

author: FutureCar Staff    

A risk of fire has been identified in more than 4,000 2023-2024 Alfa Romeo Tonale and Dodge Hornet PHEV models due to a loose battery cable. The issue arises 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. The risk of fire exists whether the vehicle is turned on or off, prompting both manufacturers to advise owners to park the vehicles outdoors until a recall repair is conducted.

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

In August, Stellantis initiated an investigation into the issue following a report from an assembly line worker at its Pomigliano Plant in Italy. The worker, while checking the torque of nuts connecting the battery cables to the integrated dual charging module, discovered a cause for concern. 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 were incorrectly tightened due to the use of wireless screwdrivers by workers.

On August 24, the plant addressed the issue by updating the screwdriver to ensure proper tightening of the nuts. Additionally, results tracking was implemented in the manufacturing execution system to improve accountability. However, all Tonales and Hornets produced before this update must now be recalled to prevent the loose cable connectors from causing fires, which can occur regardless of whether the vehicles are turned on or off.

Starting from October 27, Stellantis will contact customers and request them to bring their Tonale and Hornet SUVs 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 they are completely detached.

While there have been no reported injuries or deaths related to this issue, Stellantis has received two field reports of problems potentially linked to it. As a precautionary measure, the company advises owners of 2023-2024 Alfa Romeo Tonale and Dodge Hornet PHEVs to park their vehicles outside until the recall repair is completed to minimize the risk of fire spreading to buildings.

FutureCar Staff