BYD announces largest-ever recall of 115,000 EVs in China

BYD will recall over 115,000 Tang series and Yuan Pro vehicles in China due to design and battery-related safety issues, according to the country’s market regulator.

This is BYD’s largest recall to date.

The affected cars include 44,535 Tang series vehicles produced between March 2015 and July 2017, and 71,248 Yuan Pro EVs made from February 2021 to August 2022.

The Tang recall addresses component design flaws that may cause abnormal function, while the Yuan Pro recall relates to battery installation issues.

BYD previously recalled nearly 97,000 Dolphin and Yuan Plus EVs in September 2024 for a steering control fault, and 6,843 Fangchengbao Bao 5 plug-in hybrid SUVs in January 2025 due to fire risk.

🔗 Source: Reuters

🧠 Food for thought

Implications, context, and why it matters.

The recall’s official filings reveal engineering gaps at BYD

2015 to 2017 Tang models have a drive motor controller (the electronics that regulate power delivery to the electric motor) design flaw that triggers abnormal active discharge (unintended draining of electrical energy that generates excess heat), which scorches circuit boards and disables pure electric mode 1. 2021 to 2022 Yuan Pro units have battery sealing gaskets (seals that keep the battery enclosure watertight) that let water enter during high speed wading (driving through deep water at speed) and weaken insulation 1.
BYD will fix Tang models with a software update that switches from active discharge to motor discharge (using the traction motor to dissipate charge instead of heating electronic components) 1. Yuan Pro vehicles will get sealant to reinforce battery waterproofing 1. Since September 2024, the company has recalled nearly 97,000 Dolphin and Yuan Plus EVs over a steering control unit fault that posed fire risks, plus 6,843 Fangchengbao Bao 5 plug in hybrid off road SUVs in January 2025 2.

Fleets and insurers will move to use third party battery monitoring

BYD recalls create openings for AVILOO (a third-party battery testing company), whose AI test delivers a maker independent battery state in three minutes without automaker data 3.
Operators turn to ACCURE (a battery analytics provider) with Day Zero warranty tracking, meaning from the moment a battery enters service 4. Insurers partner with analytics firms, and TWAICE (a battery analytics software provider) equips transport operators with battery health insights for decisions 4 5.