Ford has issued an urgent safety warning to 2,865 Irish owners of its Kuga plug-in hybrid (PHEV), advising that a high-voltage battery defect could, in certain circumstances, lead to battery thermal venting and potentially a vehicle fire, with a risk of injury.
Kuga Plug-In Hybrid
The renewed warning follows an earlier safety notice issued in March 2025 affecting the same vehicles, when owners were instructed not to charge the battery due to the risk of a short circuit while driving. Ford later stated that a software update, rolled out in July 2025, would detect anomalies and prevent any fire risk.
However, owners who previously received, and in many cases installed, that update have now been sent a fresh warning letter instructing them to follow the latest guidance regardless of whether the earlier action was completed.
What owners are being told to do now
Until a permanent remedy is available, Ford is advising affected customers to:
Limit charging to a maximum of 80% and do not exceed this limit.
Use only the default “Auto EV” mode, and avoid Deep Mud and Snow modes until further notice.
Ford has said it does not yet have a fix, but anticipates a remedy by mid-year, and that customers will be contacted and instructed to arrange a dealer visit once the remedy is ready.
Vehicles affected.
Ford said the vehicles impacted were manufactured before 28th November 2023, and that unsold affected vehicles have been placed on hold.
Background and customer impact.
The Kuga crossover has been one of Ford’s strongest sellers in Ireland, with 3,124 registrations over the past three years, and more than 95% of those sales being plug-in hybrids.
Last year, some owners affected by the initial defect began legal actions against the car maker, with one Circuit Court claim alleging the vehicle was effectively worthless while repayments continued under a personal contract plan.
Asked why battery packs are not being replaced and whether compensation would be considered for owners facing difficulties selling affected vehicles, Ford said it would “define the right remedy for this issue”, adding: “We apologise for any inconvenience this may cause to our customers… We remain committed to providing our customers with safe and high-quality vehicles, addressing potential issues and responding quickly.”
Customer guidance:
Affected owners are advised to follow the instructions in Ford’s letter and contact Ford’s customer contact centre or their dealer for further assistance.
