Incorrectly torqued nuts on cables leading to both the 12-volt and high-voltage batteries in the plug-in hybrid variants of the 2023-2024 Alfa Romeo Tonale and Dodge Hornet could lead to the risk of a fire whether the vehicle is on or off. Consequently, both manufacturers of these related models recommend parking the vehicles outdoors until a recall repair is carried out.
In the United States, the problem may affect 1,875 Alfa Romeo Tonales that were built between February 9 and August 23, and 2,254 Dodge Hornets manufactured between December 13, 2022, and August 23, 2023. In all, 4,129 vehicles in the States may be impacted.
Stellantis opened an investigation into this issue in August, after its Customer Experience team received a report from an assembly line worker at its Pomigliano Plant in Italy. The employee was checking the torque of nuts connecting the battery cables to the integrated dual charging module and found a cause for concern.
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The Customer Experience team reviewed production data, as well as torque traceability data, and met with engineering to understand the design and history of the part. It reasoned that nuts were incorrectly tightened because of the wireless screwdriver workers were using.
On August 24, the plant issued a corrective update to the screwdriver so that it would tighten the nuts properly, and added results tracking to their manufacturing execution system to better account for how they were performing.
That took care of the units built after that date, but the brands must now recall all of the Tonales and Hornets made before that point in order to ensure that the loose cable connectors do not lead to a fire, which could currently happen whether the vehicles are on or off.
As a result, Stellantis will begin contacting customers on October 27, requesting them to return 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 needed, the nuts will be correctly torqued or replaced in case of complete detachment.
So far, Stellantis is not aware of any injuries or deaths due to this issue, but has received two field reports of problems potentially related to it. It recommends that until a recall repair has been completed, that 2023-2024 Alfa Romeo Tonale and Dodge Hornet PHEVs be parked outside to limit the risk that a fire spread to a building.