Kia is recalling 2,209 Niro 2022 model year electric cars. They have a high-voltage battery safety plug that may overheat and melt while driving, causing a fire or loss of power.

According to the Safety Recall Report, “the contact surfaces of the battery’s high-voltage protective plug may develop high electrical resistance over time.” Kia isn’t sure why, but the automaker believes the issue is related to “supplier bias in the production of the Female-Female terminal.”

Whatever causes electrical resistance, it can cause a big problem if it occurs while charging or while driving. In particular, the safety plug may melt, causing power loss and/or fire.

Kia first became aware of the potential problem in July 2023, when it received reports of the Niro EV shutting down while driving and the dealer discovered that the safety plug had melted. The automaker looked into the issue, but it was an isolated incident.

Despite this, the company continued its research and sent the parts to Korea for further analysis. They briefed their North American counterparts on a potentially similar incident involving a vehicle in Portugal.

In February of this year, Kia North America received reports that the Niro EV was not running. During dealer inspection, it was revealed that there was a melt safety plug. A third car with a melted safety plug was found in March, and two more cars were found in April.

Kia is unaware of any injuries, accidents, deaths or fires related to this matter, but better safe than sorry. In this regard, vehicle owners were instructed “not to charge their vehicles in the garage or other enclosed structure until the recall repairs are completed.”

During the repair, dealers will replace the safety plug with a new one with a “solid bus connection without a female-to-female terminal.”