Chinese automaker BYD (Build Your Dreams) has released its largest-ever recall, which will affect more than 115,000 Tang series and Yuan Pro models produced between 2015 and 2022. The recall, ordered by China’s State Administration for Market Regulation, fixes critical design issues in drive motor controllers and battery mounting mistakes that represent safety hazards to passengers and drivers.
Models and years affected
The recall affects two distinct groups of cars:
Tang Series (PHEV and HEV)
- Production quantity: 44,535 units
- Production period: March 2015 to July 2017
- Models affected: Tang plug-in electric and hybrid electric models
Yuan Pro (EV)
- Production quantity: 71,248 units
- Production period: February 2021 to August 2022
- Affected model: Yuan Pro battery-electric crossover
The two models represent the highest number of recalled units in the company’s history, surpassing previous measures which in total reached below 100,000 units.
Drive motor controller design flaws
In the Tang series, there is a certain design flaw in the drive motor controller’s active discharge function, and this can cause abnormal driving performance. Long-term malfunction can ultimately cause corrosion on the circuit board of the controller. Under extreme conditions, the vehicle’s pure electric drive mode will be disabled by the corrosion, forcing an unexpected shift to hybrid driving or complete loss of power on the road—serious safety concerns.
Battery installation and sealing problems
Defects during manufacturing when assembling batteries in the Yuan Pro EVs caused improperly installed power battery gaskets. The loose seal offers a point of water entry during deep puddles or heavy rain driving. Water entry compromises the insulation of the battery, which may reduce output power at random and, in the worst scenarios, cause internal short circuits or instantaneous power loss during high-speed driving.
Recall process and solutions
BYD has filed a formal recall process with the State Administration for Market Regulation, authorizing its national retail chain of dealerships to perform the necessary inspections and repairs free of charge:
Tang Series Repairs
- Inspect and replace faulty drive motor controllers.
- Implement new component designs to provide proper discharge function and prevent corrosion of circuit boards.
Yuan Pro Repairs
- Replace existing battery gaskets and reseal power battery cases with a better sealant.
- Conduct water‐ingress tests in controlled environments to validate battery housing integrity.
Customers will be contacted directly by dealerships to arrange appointments. BYD has committed to carrying out all the remedial work within six weeks of notice by letter.
Impact on BYD and the EV industry
The recall follows increasing Chinese attention to electric vehicle safety. Government authorities have only recently tightened requirements on door handle mechanisms and battery enclosures, spurred by high-profile fires and crashes. BYD recalled nearly 97,000 Dolphin and Yuan Plus EVs in September 2024 due to a fire hazard from a steering control unit, followed by a recall of 6,843 Fangchengbao Bao 5 SUVs in January 2025 for potential fire hazards.
Despite the fast growth—BYD replaced Volkswagen as China’s leading automaker in 2024—the company’s aggressive price wars have been a source of anxiety for quality control. Monthly sales collapsed in September 2025 for the first time in 18 months as domestic rivals such as Geely and XPeng gained traction. The current recall and previous safety initiatives have the capacity to cloud consumer confidence, particularly among safety‐conscious overseas markets where BYD focused on expansion.
Looking forward
To reestablish trust and mitigate future risk, BYD has pledged to strengthen quality control processes:
- Increase random-sample inspection in assembly plants.
- Enhance supplier testing of critical components, especially battery gasket seals and electronic controllers.
- Introduce advanced diagnostic software to detect the earliest warning signs of component degradation or water ingress.
These measures, if executed efficiently, have the potential not only to rectify ongoing shortcomings but also to reinforce BYD’s reputation as the global EV leader.
BYD’s recall of over 115,000 vehicles demonstrates the challenge of quick innovation and mass production in the electric vehicle industry. By correcting the design and battery installation flaws ahead of time, BYD is seeking to protect driver safety and maintain its competitive advantage nationally and internationally. Owners of Tang series and Yuan Pro models must take recall notices seriously and go to authorized dealerships in advance to have vehicles correctly repaired and safe for driving.
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