January 28, 2022 NHTSA CAMPAIGN NUMBER: 22E005000
A sudden loss of drive power increases the risk of a crash.
NHTSA Campaign Number: 22E005
Manufacturer Samsung SDI Co., Ltd.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 1,163
Summary
Samsung SDI Co., Ltd. (Samsung SDI) is recalling certain High Voltage Battery
Packs, part numbers LX68-10C790-G-PIA3AB, LX68-10C790-G-PIA3AD, 05193168AG, 05193168AH, LX68-10C790-G-PIA3AC, 05193168AE, and 05193168AF. The high voltage battery may fail, resulting in a sudden loss of drive power.
Remedy
Samusung SDI will notify and work with the affected vehicle manufacturers to replace the HV battery pack, free of charge. The manufacturer has not yet provided a schedule for recall notification. Ford owners may contact Ford customer service at 1-866-436-7332.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
SAMSUNG SDI 573 CHRONOLOGY
January 28, 2022
On or about August 25, 2021, Ford contacted Samsung SDI regarding a potential issue in connection with an overheated HV battery busbar in one vehicle, and sought Samsung SDI’s assistance in analyzing the potential issue. Samsung SDI opened an investigation to assess the situation and any potential safety issues. As part of its investigation, Ford sent the battery module from the one vehicle with the identified potential HV battery busbar to Samsung SDI Hungary for analysis, which Samsung SDI Hungary received on or about September 21, 2021.
As the investigation began, on or about August 25, 2021, as a cautionary measure given Ford’s issue identification, Samsung SDI modified welding width and area limits in order to detect non-conforming High Voltage Batteries to enhance the welding quality of the busbars upon agreement with Ford.
On or about October 1, 2021, Samsung SDI Hungary reported a preliminary initial analysis of the battery module from Ford, and tentatively identified that the HV busbar was not seated properly, causing the pad to be mounted out of position prior to busbar welding, reducing the contact area between the cell terminal and the busbar. The reduced contact area identified would be likely to cause higher resistance leading to an overheat condition. Samsung SDI’s investigation continued, and Samsung SDI continued discussions with Ford.
On or about October 13, 2021, as its investigation continued, Samsung SDI identified 47 battery cell modules to Ford with the potentially non-conforming HV busbar welding, all associated with the one Ford vehicle. On or about November 5, 2021, Ford advised Samsung SDI that Ford had decided to conduct a field action for the affected vehicle. Ford filed its 573 report with NHTSA on November 10, 2021 (NHTSA Recall No. 21V-869), which the agency acknowledged on November 18, 2021.
On or about October 20, 2021, Nex+ implemented an advanced vision inspection system to screen out any nonconforming busbar without the manual inspection with the naked eye. As a result, after on or about October 27, 2021, Samsung SDI battery cell modules began to contain busbars produced after the implementation of the vision inspection system.
Samsung SDI’s investigation continued in December 2021, during which time, on December 23, 2021, NHTSA Recall Management Division contacted Samsung SDI, requesting that Samsung SDI provide by January 6, 2022 information about the purchasers to whom Samsung SDI sold the battery pack identified in Ford’s 573 report in
NHTSA Recall No. 21V-869, and further advised that Samsung SDI may be required to submit a Part 573 report to NHTSA under 49 C.F.R. 573.3(f) if manufacturers other than Ford were supplied. Samsung SDI immediately responded to NHTSA, and requested an extension of time to January 28, 2021 given the timing of the request before the holidays and need to conduct appropriate diligence. NHTSA granted the extension on January 4, 2022.
In or about late December 2021 and through mid-January 2022, Samsung SDI’s investigation continued, and identified additional battery packs with potentially non-conforming HV busbar welding issues sold to Ford and a second manufacturer, Stellantis, and continued discussions with both Ford and Stellantis. Following all these steps and diligence, with great respect for safety, NHTSA and the process, on Tuesday, January 25, 2022, Samsung SDI decided to file a Part 573 report with NHTSA as required by 49 C.F.R. 573.3(f).
1 Affected Product
Equipment
| BRAND | PART NO. | PRODUCTION DATES |
| SAMSUNG SDI | HIGH VOLTAGE BATTERY PACK | |
4 Associated Documents
Recall Acknowledgement
RCAK-22E005-3914.pdf 645.753KB
Defect Notice 573 Report
RCLRPT-22E005-5563.PDF 217.382KB
Recall 573 Report – 3/16/2022
RCLRPT-22E005-3386.PDF 217.506KB
Miscellaneous Document – Chronology
RMISC-22E005-0247.pdf 91.711KB
Latest Recalls Documents
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- Original Japanese Manufacturing with USA Reconditioning: Manufactured in Japan for original Toyota hybrid battery systems, then professionally reconditioned in the USA using advanced American equipment under the EVG Auto Parts brand.
- Fully Reconditioned OEM Modules: These are original Japanese OEM modules that have been fully reconditioned through a comprehensive restoration process and rigorous quality testing.
- Precision Testing and Measurement: Each module is precisely measured for capacity, internal resistance, and power output to ensure optimal performance.
- High-Quality Replacement Solution: The result is original Japanese OEM modules, verified with precision testing in the USA, for replacing weak or failing cells in battery packs for Toyota Prius and other compatible hybrid models.
- Pre-Tested Voltage Range: Voltage tested at 7.6V+ before shipping, charged and ready for installation right out of the package.
SEOCONTENT-START
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-005
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Samsung SDI Co., Ltd.
Submission Date : JAN 28, 2022
NHTSA Recall No. : 22E-005
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Samsung SDI Co., Ltd.
Address : 467, Beonyeong-ro
Seobuk-gu Cheonan-si 00 31086
Company phone : 419652400
Population :
Number of potentially involved : 1,163
Estimated percentage with defect : 14 %
Equipment Information :
Brand / Trade 1 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : LX68-10C790-G-PIA3AB
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : JAN 03, 2020 – OCT 26, 2021
Brand / Trade 2 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : LX68-10C790-G-PIA3AD
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : JAN 03, 2020 – OCT 26, 2021
Part 573 Safety Recall Report 22E-005 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Brand / Trade 3 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AG
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – JAN 26, 2021
Brand / Trade 4 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AH
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – JAN 26, 2021
Brand / Trade 5 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : LX68-10C790-G-PIA3AC
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : JAN 03, 2020 – OCT 26, 2021
Part 573 Safety Recall Report 22E-005 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Brand / Trade 6 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AE
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – OCT 26, 2021
Brand / Trade 7 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AF
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – OCT 26, 2021
Description of Defect :
Description of the Defect : Welding issues identified in Samsung SDI’s manufacturing process (for certain
time periods identified in this report) during production of the high voltage
(HV) battery cell module (internal to the HV battery pack) may produce a high
resistance condition that commands the vehicle powertrain to stop.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In the event of such high resistance, the HV battery pack may become
inoperative, and the vehicle’s propulsion system may be affected, increasing
the risk of loss of motive power.
Description of the Cause : Welding issues identified in Samsung SDI’s manufacturing process (for certain
time periods identified in this report) during production of the HV battery cell
Part 573 Safety Recall Report 22E-005 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
module may produce a high resistance condition that commands the vehicle
powertrain to stop. The HV busbar pad was not seated properly and/or the
power of the welding between the cell terminal and busbar was insufficient, in
either case, causing the weak welding between the cell terminal and the
busbar.
The weak welding causes higher resistance potentially leading to the defect
condition.
Identification of Any Warning
that can Occur :
NR
Involved Components :
Component Name : Holder bus bar
Component Description : Holder to assemble HV Busbar
Component Part Number : P073-00002A
Supplier Identification :
Component Manufacturer
Name : Nex+
Address : 39, Bueongsan-gil Seonjang-myeon
Asan-si, Chungcheongnam-do Foreign States
Country : Korea, Republic of
Chronology :
NR
Description of Remedy :
Description of Remedy Program : Samsung SDI will cooperate with affected vehicle manufacturers, including
Ford and Stellantis, to notify owners and instruct them to take their
vehicle to the appropriate dealer and replace the entire HV battery pack at
no cost to the owner. Reimbursement will be consistent with the vehicle
manufacturers’ respective reimbursement policies.
Part 573 Safety Recall Report 22E-005 Page 5
The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs
from Recalled Component :
The remedy battery cell module contains properly seated and welded
busbars.
Identify How/When Recall Condition
was Corrected in Production :
Samsung SDI’s good faith information and belief is that it has reasonably
identified the conditions arising in connection with the battery packs
identified above.
Recall Schedule :
Description of Recall Schedule : To be determined. Upon approval, owner notification letters will be
mailed no later than 60 days after submission of this report.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : Ford Motor Company
Address : 330 Town Center Drive Suite 500
Dearborn MI 48126-2738
Country : US
Company Phone : 8664367332
Name : Stellantis
Address : 800 Chrysler Drive
Auburn Hills MI 48326-2757
Country : US
Company Phone : 8008531403
* NR – Not Reported
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-005
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Samsung SDI Co., Ltd.
Submission Date : MAR 16, 2022
NHTSA Recall No. : 22E-005
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Samsung SDI Co., Ltd.
Address : 467, Beonyeong-ro
Seobuk-gu Cheonan-si 00 31086
Company phone : 419652400
Population :
Number of potentially involved : 1,163
Estimated percentage with defect : 14 %
Equipment Information :
Brand / Trade 1 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : LX68-10C790-G-PIA3AB
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : JAN 03, 2020 – OCT 26, 2021
Brand / Trade 2 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : LX68-10C790-G-PIA3AC
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : JAN 03, 2020 – OCT 26, 2021
Part 573 Safety Recall Report 22E-005 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Brand / Trade 3 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : LX68-10C790-G-PIA3AD
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : JAN 03, 2020 – OCT 26, 2021
Brand / Trade 4 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AE
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – OCT 26, 2021
Brand / Trade 5 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AF
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – OCT 26, 2021
Part 573 Safety Recall Report 22E-005 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Brand / Trade 6 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AG
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – JAN 26, 2021
Brand / Trade 7 : Samsung SDI
Model : High Voltage Battery Pack
Part No. : 05193168AH
Size : NR
Function : Propulsion
Descriptive Information : This recall campaign refers to NHTSA Part 573 filing 21V-869 reported by the
Ford Motor Company using the subject components. Recall campaign population
has been defined based on welding issues identified in Samsung SDI’s
manufacturing process and production data. Samsung SDI has identified battery
packs with potentially non-conforming HV busbar welding issues sold to Ford
and a second manufacturer, Stellantis. 1163 total units that may be affected
(Ford 1139, Stellantis 24).
Production Dates : OCT 12, 2020 – JAN 26, 2021
Description of Defect :
Description of the Defect : Welding issues identified in Samsung SDI’s manufacturing process (for certain
time periods identified in this report) during production of the high voltage
(HV) battery cell module (internal to the HV battery pack) may produce a high
resistance condition that commands the vehicle powertrain to stop.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In the event of such high resistance, the HV battery pack may become
inoperative, and the vehicle’s propulsion system may be affected, increasing
the risk of loss of motive power which may increase the risk of a crash.
Description of the Cause : Welding issues identified in Samsung SDI’s manufacturing process (for certain
time periods identified in this report) during production of the HV battery cell
Part 573 Safety Recall Report 22E-005 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
module may produce a high resistance condition that commands the vehicle
powertrain to stop. The HV busbar pad was not seated properly and/or the
power of the welding between the cell terminal and busbar was insufficient, in
either case, causing the weak welding between the cell terminal and the
busbar.
The weak welding causes higher resistance potentially leading to the defect
condition.
Identification of Any Warning
that can Occur :
NR
Involved Components :
Component Name : Holder bus bar
Component Description : Holder to assemble HV Busbar
Component Part Number : P073-00002A
Supplier Identification :
Component Manufacturer
Name : Nex+
Address : 39, Bueongsan-gil Seonjang-myeon
Asan-si, Chungcheongnam-do Foreign States
Country : Korea, Republic of
Chronology :
NR
Description of Remedy :
Description of Remedy Program : Samsung SDI will cooperate with affected vehicle manufacturers, including
Ford and Stellantis, to notify owners and instruct them to take their
vehicle to the appropriate dealer and replace the entire HV battery pack at
no cost to the owner. Reimbursement will be consistent with the vehicle
manufacturers’ respective reimbursement policies.
Part 573 Safety Recall Report 22E-005 Page 5
The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs
from Recalled Component :
The remedy battery cell module contains properly seated and welded
busbars.
Identify How/When Recall Condition
was Corrected in Production :
Samsung SDI’s good faith information and belief is that it has reasonably
identified the conditions arising in connection with the battery packs
identified above.
Recall Schedule :
Description of Recall Schedule : Not applicable (Samsung SDI does not have dealers and/or distributors,
and Samsung SDI understands that notice is being issued by Ford and
Stellantis). Samsung SDI understands that Ford and Stellantis will
provide recall completion rate information required by 49 CFR 573.7
because they will be conducting the recall campaign. See 49 CFR 573.3(f)
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : Ford Motor Company
Address : 330 Town Center Drive Suite 500
Dearborn MI 48126-2738
Country : US
Company Phone : 8664367332
Name : Stellantis
Address : 800 Chrysler Drive
Auburn Hills MI 48326-2757
Country : US
Company Phone : 8008531403
* NR – Not Reported
**************************************************************************************************************
SEOCONTENT-END
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