Key Takeaways
1. Nissan has issued an urgent recall for approximately 19,077 Leaf vehicles due to overheating issues during Level 3 fast charging, posing a fire risk.
2. The overheating problem is linked to lithium-ion battery deposits causing increased electrical resistance, and owners are advised to avoid Level 3 fast charging until resolved.
3. A complimentary software update will be offered by Nissan dealerships to fix the battery control system, with notifications to owners starting October 24, 2025.
4. Nissan is facing production challenges with the new Leaf model, reducing output at its Tochigi plant by over half due to a critical battery shortage.
5. The production delays and safety issues threaten Nissan’s restructuring efforts, which rely on the success of the new Leaf with improved range and SUV styling.
Nissan is facing serious challenges with its electric vehicles in the United States. The company has issued an urgent recall due to overheating issues during Level 3 fast charging (DC charging). The National Highway Traffic Safety Administration (NHTSA) has confirmed this recall under campaign number 25V655000. Approximately 19,077 Nissan Leaf vehicles worldwide from the 2021 and 2022 model years, which have a Level 3 fast charging port (DC charging via CHAdeMO), are involved.
Problem with Batteries
The main issue stems from the lithium-ion battery, where increased electrical resistance due to deposits in the battery cells can lead to overheating during Level 3 fast charging. This overheating creates a serious safety hazard and raises the risk of fire incidents.
To mitigate this problem, owners are advised to avoid using Level 3 fast charging until the defect is fixed. Nissan dealerships will provide a complimentary software update for the battery control system in the affected electric vehicles. The NHTSA plans to send notification letters to vehicle owners starting October 24, 2025. Nissan’s internal recall code for this issue is R25C8.
Timing of the Recall
This safety issue comes at a bad time for Nissan, as the company reported a considerable net loss last fiscal year. They are counting on the newly launched third generation of the Nissan Leaf to help them succeed in their restructuring efforts.
The new Nissan Leaf features SUV styling for the first time and boasts a significant improvement over its predecessor, with a promised range of up to 373 miles/600 kilometers. This model is seen as a vital part of the company’s restructuring plan.
Production Challenges
However, this important new electric vehicle is facing serious production challenges. According to Nikkei Asia, Nissan has reduced production of the new Leaf at its Tochigi plant in Japan by over half for the period from September to November, affecting thousands of units that had to be canceled or delayed.
The reason for these production cuts is a critical shortage of batteries. The Tochigi plant obtains its batteries from AESC, a subsidiary of Nissan. The production yield of these necessary batteries has not improved as anticipated, causing supply chain bottlenecks.
It is still unknown how much the production of the Nissan Leaf at the Sunderland plant in the UK is impacted. Nevertheless, the delays in Japan underlines the significant challenges facing Nissan, whose restructuring efforts have been severely threatened by issues in their electric mobility sector.
NHTSA | Nikkei Asia
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