BYD to recall nearly 90,000 hybrids in China over battery defects
- ByStartupStory | December 1, 2025
Qin PLUS DM-i Sedans Face Power Output Risks From Production Inconsistencies
Chinese electric vehicle giant BYD will recall 88,981 Qin PLUS DM-i plug-in hybrid sedans due to manufacturing inconsistencies in power battery packs that may limit output and pose safety hazards. The vehicles, produced between January 2021 and September 2023, could experience restricted electric drive mode under extreme conditions, prompting an immediate action ordered by China’s State Administration for Market Regulation following a defect investigation.
Two Batches Affected By Battery Pack Issues
The recall covers two production batches: 52,890 units built from September 26, 2021, to September 23, 2023, and 36,091 vehicles manufactured between January 7, 2021, and September 30, 2022. Inconsistencies during battery assembly may reduce power delivery, potentially disabling pure-electric operation and increasing accident risks if drivers lose acceleration unexpectedly.
Dealers will push free over-the-air (OTA) software updates to detect anomalies via dashboard alerts. Confirmed faults trigger complimentary battery pack replacements at service centers, minimizing owner inconvenience while addressing root causes across affected models.
Latest In Series Of High-Profile Recalls Amid Sales Pressures
This action follows BYD’s mid-October recall of over 115,000 Tang and Yuan Pro vehicles for design flaws and battery ingress risks, plus September’s 97,000 Dolphin and Yuan Plus units over steering fire hazards—totaling more than 210,000 vehicles in 2025 alone. October sales fell 12% year-over-year after a 33% Q3 profit drop, intensifying scrutiny on quality amid China’s brutal EV price wars.
BYD’s DM-i hybrids, central to its dominance over Tesla in plug-ins, underscore production scaling challenges as volumes exceed 3 million annually. The Qin PLUS remains a bestseller, but regulators demand transparency to maintain consumer trust in rapid-growth NEVs.
Response Measures And Broader Implications
BYD commits to swift execution, leveraging OTA diagnostics for efficiency over physical inspections. Owners receive notifications via app and SMS, with service prioritized to avoid disruptions. The company maintains no immediate accidents linked to the defect, framing it as proactive risk mitigation.
This recall highlights China’s maturing oversight of EV battery integrity, where pack consistency proves critical at gigafactory scales. Globally, similar issues plague competitors—GM recalled 70,000+ Ultium EVs, Hyundai 145,000 Ioniq 5s—yet BYD’s frequency raises questions on supplier quality amid vertical integration.
Market Reaction And Strategic Context
Shares dipped modestly post-announcement, reflecting investor acclimation to recalls in high-volume segments. BYD eyes Europe expansion with Atto 3 exports, but domestic hybrid dominance (50%+ PHEV share) demands flawless execution.
Forward, enhanced battery monitoring via OTA and AI anomaly detection could prevent escalations, positioning BYD to lead safe scaling. As hybrids bridge EVs, such transparency bolsters long-term credibility despite short-term headlines.
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