Less than a month ago, BMW announced a recall impacting more than 70,000 of its electric vehicles, revealing a software issue that could cause the high-voltage system to shut down unexpectedly. Fast forward to July, and the German brand has issued another recall for several of its EVs in the United States. This time, the recall is also related to battery cell modules that may have been assembled incorrectly.

Read: BMW Recalls Thousands Of EVs That Can Lose Power While Driving

According to the recall notice, the issue stems from the process of compressing individual battery cells to form a single module. In this case, BMW says the force used to combine the cells within the module may have exceeded its specifications. This means that over the lifetime of the vehicle, and when combined with repeated charging sessions, the module frame could fail.

What Can Go Wrong

If the frame does weaken or fail, it could lead to a shutdown of the high-voltage system. This would result in a total loss of propulsion, creating a potential crash risk. There’s also an increased chance of fire if a failure occurs.

The recall impacts a total of 136 vehicles. Oftentimes, only a small percentage of affected vehicles are thought to have the issue. That’s not the case here, as BMW believes that all 136 vehicles have battery cell modules that may not have been assembled to specifications.

Those include 2022-2025 BMW iX models manufactured from November 3, 2021, and February 14, 2024, as well as 2023-2024 BMW i7s built from June 12, 2023, to July 19, 2023, and 2022-2023 BMW i4s assembled from June 2, 2022, to May 11, 2023.

Notably, vehicles involved in the recall may not suffer from any issues for quite some time. In its analysis, BMW says that damage to the module frame of impacted models may not occur until the latter part of 2026. Nevertheless, it’s decided now is the time to issue a recall.

Owners will begin receiving notification letters on September 5. Dealers have already been instructed to replace the affected high-voltage battery cell modules on all impacted vehicles.

BMW is recalling 70,852 EVs because their electric drive motor software may shut down the high-voltage system. This can result in a loss of drive power, which increases the risk of a crash.

An assortment of models are impacted including the 2022-2025 i4, 2022-2024 iX, and 2023-2024 i7. BMW is also recalling 4,674 i5s from the 2024 model year.

More: BMW Introduces New i4 M60 With 593 HP

According to the safety recall report, the electric drive motor software may “erroneously detect a double-isolation condition.” If this occurs, the high-voltage system will shut down for approximately 15-20 seconds following a warning message. This will effectively leave drivers coasting, but the government noted the steering and braking system will continue to operate.

BMW began investigating the issue in 2021 and initially believed debris could have gotten into electric motors and affected their performance. However, there was a “very low number of claims” at the time and this made it hard to pinpoint the problem.

Despite the difficulties, the automaker spent years looking into the issue and eventually focused on the possibility of a loss of propulsion due to detection of a double-isolation condition. This analysis suggested the “vehicle software could not determine, whether a detected double-isolation condition was, in fact, a true double-isolation condition, which warranted a high-voltage system shutdown or, was, in fact, only a single-isolation condition.” This is important as a double-isolation condition triggers a shutdown of the high-voltage system as part of a fail-safe measure to prevent an electric shock or a “thermal risk.”

BMW believes they have received approximately 43 warranty claims related to the issue, which resulted in loss of propulsion at speeds greater than 20 mph (32 km/h). Thankfully, the company isn’t aware of any accidents or injuries related to the problem.

To address the issue, BMW will install new electric drive motor software as part of an over-the-air update. Customers can also have this installed at dealerships and owner notifications are slated to go out on August 5.