In a one-two punch to its electric vehicle ambitions, Nissan Motor Company is grappling with a serious safety recall affecting thousands of Leaf models in the U.S. while simultaneously facing massive production cuts for the vehicle's critical successor, casting a shadow over the automaker's restructuring strategy.
Urgent NHTSA Recall: Fire Hazard for Leafs During Fast Charging
The first and most immediate crisis is an urgent safety recall announced by the National Highway Traffic Safety Administration (NHTSA). The federal agency has officially confirmed recall campaign number 25V-655, impacting approximately 19,077 Nissan Leaf units from the 2021 and 2022 model years globally. The recall specifically targets vehicles equipped with a CHAdeMO port for Level 3 DC fast charging.
The core of the problem lies within the vehicle's lithium-ion battery. According to the official filing, increased electrical resistance caused by microscopic deposits inside the battery cells can lead to dangerous overheating during a fast-charging session. This overheating poses an acute safety risk, significantly increasing the potential for a fire.
As an immediate and critical remedy, Nissan and the NHTSA are urging all owners of affected Leaf models to immediately refrain from using any Level 3 DC fast chargers until the necessary repair has been performed. The automaker has stated that the permanent fix involves a free software update for the Leaf's Battery Management System (BMC), which will be installed at authorized Nissan dealerships.
The software is designed to better monitor and manage battery cell temperature and resistance during charging cycles, preventing the dangerous overheating condition. Notification letters to registered vehicle owners are scheduled to be mailed out starting October 24, 2025. Nissan's internal code for this campaign is R25C8.
Restructuring Strategy Under Pressure: The Leaf as a Beacon of Hope
This safety scandal could not have come at a worse time for the Japanese automaker. After reporting a significant net loss in the previous fiscal year, Nissan is in the midst of a deep corporate restructuring. Central to its revival plan is the success of its next-generation electric vehicles, with the newly introduced third-generation Nissan Leaf positioned as a flagship beacon of hope.
The new Leaf, which abandons its iconic hatchback design for a more popular SUV-style body, promises a monumental leap in capability. With a targeted range of up to 373 miles (600 kilometers) per charge, it was designed to be a competitive and compelling offering in the crowded EV market, a key model intended to drive Nissan back to profitability and relevance.
Battery Shortage Slashes Production of New Model by Over Half
However, this crucial new model is already facing a severe setback before it can even reach its full market potential. According to a recent report from Nikkei Asia, Nissan has been forced to slash production of the new Leaf at its flagship Tochigi plant in Japan by more than half for the critical months of September through November.
The reason? An acute shortage of the very batteries that power the vehicle. The Tochigi plant sources its battery packs from AESC, a Nissan subsidiary. Reports indicate that the production yield—the number of batteries that meet quality standards—has failed to improve as expected, creating a crippling bottleneck in the supply chain. This has led to the cancellation or postponement of thousands of units, a devastating blow for a model carrying the company's future on its shoulders.
While it remains unclear to what extent European production of the Nissan Leaf in Sunderland, UK, is affected, the delays in Japan highlight the profound challenges facing the automaker. The simultaneous crises—a safety recall undermining trust in its current EV technology and a production nightmare hampering its future one—create a perfect storm. For a glimpse into Nissan's ambitious original vision for this pivotal model, industry watchers have been analyzing previews like the one from GSMGoTech, which detailed the specs intended to shake up the EV market.
The success of Nissan's restructuring strategy, now massively jeopardized, hinges on its ability to swiftly and confidently resolve both the immediate safety concerns of its current customers and the deep-seated supply chain issues threatening its future.
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