2023 Porsche Taycan and Audi E-Tron GT recalled due to battery seal

The Porsche Taycan and Audi e-tron GT electric cars have been recalled to address a battery leak issue.

The two electric cars are based on the same J1 platform and share several key components, including the battery seal. Both Porsche and Audi switched to Teroson sealant during the period the affected cars were in production, and it may have been applied in insufficient amounts around the battery pack, according to documents filed with the National Highway Traffic Safety Administration (NHTSA). This “could allow fluid to build up in the battery.”

The recall covers 4,777 Taycan vehicles built between September 23, 2022 and August 3, 2023, and 1,899 E-Tron GT vehicles built between the start date and August 28, 2023. All vehicles built before and after those dates will not be affected.

NHTSA estimates that 3% of affected vehicles have a defective battery seal. The recall includes most Taycan models, including the sedan and Cross Turismo/Sport Turismo wagon. Both the base E-Tron GT model and the RS E-Tron GT performance model are also included in the recall.

“Dealers will test the battery for leaks and replace the battery when necessary free of charge,” according to NHTSA. So it looks like some owners may end up having to get new battery packs. It’s unclear whether a particular supplier is in trouble here, but if a large number of battery packs need to be replaced, this could turn into a very costly mistake.

These models were among the first to get 800-volt charging, but the problem has nothing to do with that. It’s also not the first electric vehicle to be recalled due to a leaky battery issue.

Porsche Taycan 2023

The GMC Hummer EV was also recalled last year due to battery sealing issues, in this case because the surfaces the sealant was applied to were not properly prepared, meaning the sealant didn’t adhere well enough. The Audi E-Tron SUV was recalled in 2019 for what appears to be a similar problem. At the time, the automaker warned that the condition could cause a “thermal event.”

It’s a very different battery issue from the recalls that use LG Energy Solution cells in a number of models, most of which appear to be related to the cells themselves — and in some cases including the Chevrolet Bolt EV that has manufacturing issues. That led to GM paying $1.9 billion to help cover the costs of the recall — with many Bolt EV buyers getting new vehicles.