Ford Kuga PHEV NMC battery fire risk problem
What I like about Ford:
- Well-equipped with plenty of features.
- Great driving dynamics – the handling feels sharp and responsive.
- Very low fuel consumption (around 2 l/100 km).
- Up to 75 km of pure electric driving in my experience.
My concerns:
Recently, I contacted my Ford service center and discovered that my vehicle is affected by an active recall:
https://www.ford.de/hilfe/rueckruf-details/
After spending about three weeks researching the issue myself (using AI tools, Google, technical documentation, and discussions with a friend who is a professor at the Faculty of Electrical Engineering), I have to admit that I no longer feel comfortable with this NMC battery technology.
The Ford Kuga PHEV uses a 14.4 kWh lithium-ion NMC (Nickel-Manganese-Cobalt) battery.
From what I understand, this battery chemistry carries an inherent risk of thermal runaway if an individual cell develops an internal short circuit. In such cases, localized overheating can occur and potentially lead to cell venting or a fire.
- The official recall documentation from the U.S. Department of Transportation and the National Highway Traffic Safety Administration (NHTSA) highlights these concerns:
https://static.nhtsa.gov/odi/rcl/2026/RCLRPT-26V091-2283.pdf
(Recall 25SC4, which appears to be the same issue referenced on the Ford Germany recall page.)
From the report:
"On December 16 and 17, 2025, Ford received two European field reports of cell vents occurring on Ford Kuga vehicles produced subsequent to the 25SC4 recall population."
Another related document:
- https://static.nhtsa.gov/odi/rcl/2024/RMISC-24V954-4969.pdf
The report states:
"On September 4, 2024, Ford's Critical Concern Review Group (CCRG) opened an investigation into three field reports from Europe describing battery thermal venting occurring in PHEV vehicles. The venting incidents occurred between April 2024 and August 2024."
One thing I do appreciate is the transparency shown by Ford and the U.S. regulatory authorities. The issue has been openly documented and investigated rather than hidden.
However, I am struggling to understand how this problem can be permanently solved through software alone. While advanced battery monitoring may reduce the risk by detecting abnormal behavior earlier, it does not eliminate the possibility of an internal cell defect.
For that reason, I have personally decided not to charge the vehicle for now and instead use it as a regular hybrid (similar to an FHEV).
This is a fundamental problem by NMC technology itself. If it can not solve short-circuit problem then this is a failure. I read that even if LFP battery type has short-circuit there is only smoke, no fire.
What is more valuable:
- having a perfect car or a possibility of your house on fire?
Does anyone have any insight into how Ford plans to provide a long-term solution for this issue?
As far as I know, similar battery-related concerns have also affected vehicles from other manufacturers, including:
- Volkswagen Group
- BMW
- Mercedes-Benz
- and companies within the Stellantis Group.
I'd be interested to hear other owners' opinions or any technical insights regarding Ford's planned fix.