Key Takeaways
- The Numbers: 88,981 Qin Plus DM-i vehicles recalled.
- The Defect: Manufacturing issues in the battery pack can cause voltage instability.
- The Risk: Vehicles may lose power or fail to operate in EV mode, posing a safety hazard.
- The Trend: This is BYD’s third major recall in 2025, totaling over 210,000 units.
Introduction
When you’re the biggest, the spotlight burns the brightest. BYD, the titan of the Chinese electric vehicle market, has hit another speed bump. In late November 2025, the company announced the recall of nearly 89,000 plug-in hybrid vehicles due to a potentially dangerous battery defect.
While recalls are a normal part of the automotive industry—even for stalwarts like Toyota and Ford—the frequency of BYD’s recent quality issues raises questions. Is the company’s breakneck pace of expansion coming at the cost of quality control?
Background: A Year of Highs and Lows
The Early Days
BYD built its reputation on its battery technology. Starting as a battery manufacturer for cell phones, they leveraged that expertise to build safe, reliable, and affordable EVs. The “Blade Battery” was hailed as a game-changer for safety.
Recent Developments
2025 has been a mixed bag. On one hand, BYD’s international expansion is exploding, with new plants in Brazil and Hungary. On the other, domestic sales growth has slowed, and quality gremlins are appearing. Earlier this year, recalls affected the Dolphin and Yuan Plus models.
Current State
This latest recall affects the Qin Plus DM-i, one of BYD’s best-selling sedans. The specific vehicles were manufactured between January 2021 and September 2023.
Understanding the Defect
The issue lies deep within the high-voltage battery pack.
How It Works
According to filings with China’s State Administration for Market Regulation (SAMR), the defect involves the battery management system (BMS) and the physical cell connections. Manufacturing variances can lead to voltage instability across the cell groups.
Why It Matters
If the voltage fluctuates beyond safe limits, the BMS may trigger a “limp mode” or cut power entirely to prevent thermal runaway (fire).
- Best Case: The car displays a warning and limits power.
- Worst Case: The car loses propulsion while driving, increasing the risk of a crash.
The Data
Key Statistics:
- Vehicles Affected: 88,981 units.
- Model: Qin Plus DM-i (PHEV).
- Production Dates: Jan 2021 - Sept 2023.
- Total 2025 Recalls: ~210,000+ vehicles.
Industry Impact
Impact on Brand Reputation
In China, social media reaction has been swift. While loyalists defend the brand, potential buyers are becoming wary. “Made in China” has fought hard to shed the stigma of poor quality; recurring recalls from the national champion don’t help the cause.
Impact on Global Expansion
International markets are watching. As BYD pushes into Europe and Australia, regulators there will be scrutinizing these recalls. If similar issues appear in export models, it could derail their aggressive global growth targets.
Challenges & Limitations
- Quality vs. Quantity: BYD produced over 3 million cars last year. Scaling manufacturing that quickly puts immense strain on supply chains and quality assurance (QA) processes.
- Supplier Control: While BYD is vertically integrated, they still rely on a vast network of component suppliers. Ensuring every part meets spec at that volume is a monumental logistical challenge.
What’s Next?
Short-Term (1-2 years)
BYD will likely implement stricter QA protocols and may slow down production slightly to address these systemic issues. The fix for the current recall involves a software update for some and a physical battery pack replacement for others—a costly endeavor.
Long-Term (5+ years)
This is a maturity test. Every major automaker goes through “recall hell” at some point. If BYD learns from this and hardens their processes, they will emerge stronger. If they ignore it in favor of raw volume, they risk long-term brand damage.
Conclusion
The November 2025 recall is a wake-up call. BYD has proven it can build cars fast and cheap. Now, it must prove it can build them perfect, every time. For the consumer, it’s a reminder that even the industry leaders aren’t immune to growing pains. As BYD fixes these 89,000 cars, the world will be watching to see if they also fix the process that built them.