BYD Recalls 20% of October Sales Over Potential Battery Risks

TLDRs;

• BYD recalls nearly 90,000 hybrids over potential battery defects in China.
• Affected vehicles represent 20% of BYD’s October 2025 sales figures.
• Remote software updates will fix battery issues and alert drivers automatically.
• Recall highlights ongoing quality control challenges in China’s growing NEV market.

China’s electric vehicle giant BYD has announced a major recall impacting nearly 90,000 of its plug-in hybrid models after regulators flagged potential battery defects that could compromise vehicle performance and safety.

The recall highlights ongoing challenges for China’s rapidly growing New Energy Vehicle (NEV) sector, especially in maintaining consistent quality amid accelerated production.

Battery Flaws Prompt Large Recall

The recall affects 88,981 BYD Qin Plus DM-i sedans manufactured between January 2021 and September 2023. Regulators from China’s State Administration for Market Regulation identified inconsistencies in the battery packs, which could limit power output and, in rare cases, prevent the vehicles from operating in pure electric mode.

To address the issue, BYD will deploy a remote over-the-air (OTA) software update to the affected vehicles. Drivers will be alerted if faults are detected, and BYD has committed to replacing any defective battery packs at no cost.

The affected units represent approximately 20% of the company’s total vehicle sales for October 2025, underscoring the recall’s commercial significance.

Recurring Quality Challenges in China

This recall follows closely on the heels of BYD’s earlier October action, which involved over 115,000 Tang and Yuan Pro models due to design and battery safety defects. The close timing of these two recalls suggests systemic challenges in quality management, particularly as Chinese automakers expand production rapidly to meet growing domestic and international demand.

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China has recorded 3,230 recalls affecting 120 million vehicles as of September 2025, demonstrating both the scale of the market and the prevalence of quality issues.

The prolonged production window of the affected Qin Plus DM-i sedans, spanning over 2.5 years, indicates that the defect went undetected for a significant period, raising questions about monitoring and inspection processes during BYD’s rapid growth phase.

OTA Updates and Regulatory Oversight

The recall also illustrates the increasing role of OTA software updates in maintaining vehicle safety. China now mandates filing for OTA updates, especially for core features such as autonomous driving, and requires automakers to notify authorities promptly about accidents and driver-assistance software events. These regulations, effective January 2026, aim to improve transparency and reduce risks associated with software-related defects.

Battery analytics firms and third-party monitoring vendors are positioned to assist manufacturers and insurers by identifying anomalies before they escalate into safety hazards.

Experts predict that OTA installation rates in China could reach 90% by 2030, making remote software fixes a critical tool for fleet safety management.

Market Implications and Consumer Confidence

While the recall covers only 2.4% of BYD’s 2025 sales to date, the scale and visibility of the defect could influence consumer confidence in the brand.

For a company that sold 3.7 million vehicles in the first ten months of the year, addressing quality issues quickly is crucial to sustaining market momentum and reinforcing trust in China’s broader NEV industry.

As demand for electric and hybrid vehicles grows, automakers like BYD must balance rapid innovation and production with rigorous quality controls.

Recalls such as this underline the importance of stringent oversight and the adoption of modern tools like OTA updates and battery monitoring systems to safeguard both consumers and the industry’s reputation.