Jeep Wrangler 4xe and Grand Cherokee 4xe Recalled Again for Fire Risk and Engine Defects
What’s the Problem
Jeep plug-in hybrid electric vehicles — including certain 2020–2025 Jeep Wrangler 4xe and 2022–2026 Jeep Grand Cherokee 4xe SUVs — are the subject of multiple serious safety recalls involving battery fire risks and engine defects that can lead to catastrophic failure, fires, or loss of propulsion. Two significant recall campaigns — one involving high-voltage battery fire hazards (NHTSA Recall 25V-741, Jeep Recall 68C) and another involving engine contamination (NHTSA Recall 25V-766 / Jeep Recall 78C) — have been issued by Chrysler under the oversight of the National Highway Traffic Safety Administration (NHTSA).
These defects raise substantial safety concerns because of the potential for unintended fires while parked or driving, total engine failure, or sudden loss of drive power even without prior warning. Repairs for both issues are in progress but, as of the most recent notices, definitive remedies are not yet available.
Allegations
Battery Fire Risk (Recall 68C / 25V-741)
Chrysler identified that certain high-voltage battery packs in Jeep 4xe PHEVs may contain internal cell separator damage. This damage can lead to internal electrical short circuits and thermal events that ignite a fire. Owners have been advised to park their vehicles outside and refrain from charging the battery until a repair is completed. Chrysler is aware of numerous fires, including some in vehicles previously remedied under older recall actions, and at least one injury potentially related to this defect.
Engine Sand Contamination (Recall 78C / 25V-766)
A separate safety defect involves sand and debris left inside engines during the casting process. According to recall documents and owner community reports, leftover casting sand may contaminate internal engine components, which can lead to engine damage, catastrophic failure, loss of propulsion, or a fire originating in the engine compartment. In response, Chrysler and NHTSA have determined that this is a safety defect requiring recall action under campaign 78C (NHTSA 25V-766). Owners of certain 2023–2025 Grand Cherokee 4xe and 2024–2025 Wrangler 4xe vehicles have reportedly received notices about this engine issue.
Owners discussing this recall on enthusiast forums have described receiving notice that their vehicle engine “may be contaminated with sand from the casting process,” with potential outcomes including fire or engine failure — and note that no effective remedy is currently available.
Recall / TSB
Battery Pack Fire Risk Recall — 68C (NHTSA 25V-741)
Affected Vehicles: Approximately 320,065 Jeep Wrangler and Grand Cherokee PHEV models built with high-voltage battery packs that might experience separator damage.
Recall Campaign: Jeep Recall 68C, NHTSA Recall 25V-741.
Risk: Potential for thermal events and fires in the battery pack while the vehicle is parked or driven.
Current Remedy Status: A final repair is not yet available; interim owner instructions focus on risk mitigation.
Engine Contamination Recall — 78C (NHTSA 25V-766)
Affected Vehicles: Jeep Grand Cherokee 4xe (2023–2025) and Jeep Wrangler 4xe (2024–2025) vehicles whose engines may have been contaminated during casting.
Recall Campaign: Jeep Recall 78C, NHTSA Recall 25V-766.
Risk: Sand contamination within internal engine components that may lead to catastrophic engine failure, loss of propulsion, or fire.
Current Remedy Status: A definitive repair is still under development; owner letters and VIN lookups have been initiated.
Owners should check both recall statuses via NHTSA’s VIN lookup tool and with their dealerships. Multiple concurrent recall actions may apply to the same vehicle.
Symptoms
Owners of affected vehicles may notice no outward symptoms prior to a safety incident. However, possible consequences include:
No warning before a battery fire occurs.
Unintended fires while parked or driving due to battery thermal events.
Engine failure that may cause sudden loss of drive power.
Engine compartment fire due to internal engine contamination.
Repeated service visits related to battery or engine issues.
Due to the latent nature of these defects, a vehicle may appear to drive and function normally until a defect manifests suddenly.
How to Proceed
If you own a potentially affected Jeep Wrangler 4xe or Grand Cherokee 4xe:
Check your vehicle’s VIN on NHTSA’s official recall lookup tool to confirm whether it is subject to recall 68C (battery), recall 78C (engine), or both.
Follow all interim safety instructions from Jeep and NHTSA, including parking outside and avoiding charging until the battery issue is addressed.
Schedule inspections with an authorized Jeep dealership for both recall campaigns.
Keep detailed records of all communications, notices, service visits, and repair attempts.
Contact Valero Law for a free evaluation to understand your California Lemon Law rights and mitigate some of the loss of value of the vehicle you cannot drive.
Call Valero Law
If you own a Jeep Wrangler 4xe or Grand Cherokee 4xe that has been subject to multiple recalls — including the battery recall (68C / 25V-741) and the engine sand contamination recall (78C / 25V-766) — and you are experiencing repeated safety issues, repeated repair attempts, or unresolved defects, you may have rights under California’s Lemon Law and other consumer protection statutes.
Defects that compromise safety, result in repeated repairs, or cannot be timely remedied may qualify your vehicle as a “lemon.” For experienced legal guidance and help evaluating your potential claim:
Call Valero Law, APC at (424) 299-4447 or complete our free Lemon Law case evaluation form today.