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New (Sept 2023) global stop sale on all Taycans? Recall APB2 updated Sept 11, 2023

WasserGKuehlt

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So it sounds like cars without the Teroson sealant had leaks, hence the introduction of the sealant in September of 2022. To put it in your analogy: there was a bug, fix was applied, fix didn't work, additional fix was applied, only cars with inadequate fix were recalled. Cars with no fix were not recalled. Why?
The report also says "non-US cars", so if I were to guess, they were not recalled because the existing law framework (in whatever locale those batteries did leak) did not require the issuance of a recall. ?‍♂

And, to further the analogy, the original heisenbug was converted into a steady repro by the new feature.
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snstevens

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Yes, but the same report says those cars had leak reports:

So it sounds like cars without the Teroson sealant had leaks, hence the introduction of the sealant in September of 2022. To put it in your analogy: there was a bug, fix was applied, fix didn't work, additional fix was applied, only cars with inadequate fix were recalled. Cars with no fix were not recalled. Why?
Late comer to this discussion - My reading of the Electrek article and the NHTSA website is different. It is my understanding that there has always been a "battery sealant" to prevent moisture from entering the HV battery. Check this article out that reads in part --

"Porsche has recalled all variants of the 2023 Taycan over potentially insufficient battery sealant. The automaker introduced a new battery sealant material last September for the beginning of 2023 model-year production and discovered that the sealant may not be sufficient."
"In its recall notice, submitted to NHTSA on September 1, Porsche says it began receiving reports of insufficient insulation values in March 2023, and a month later, determined that one U.S.-market car was affected. Two further U.S. Taycans were found to have insufficient sealant after a dashboard warning message prompted owners to bring cars to dealers for examination."

So Porsche moved to a Teroson sealant (typical supplier management - maybe cheaper?). The original Teroson formulation turned out to be insufficient, so Teroson provided an upgraded formulation . It is simply the cars produced from March - August that are effected, not cars produced earlier using the original sealant, and that would include cars destined for the US market.
 
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whitex

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Late comer to this discussion - My reading of the Electrek article and the NHTSA website is different. It is my understanding that there has always been a "battery sealant" to prevent moisture from entering the HV battery. Check this article out that reads in part --

"Porsche has recalled all variants of the 2023 Taycan over potentially insufficient battery sealant. The automaker introduced a new battery sealant material last September for the beginning of 2023 model-year production and discovered that the sealant may not be sufficient."
"In its recall notice, submitted to NHTSA on September 1, Porsche says it began receiving reports of insufficient insulation values in March 2023, and a month later, determined that one U.S.-market car was affected. Two further U.S. Taycans were found to have insufficient sealant after a dashboard warning message prompted owners to bring cars to dealers for examination."

So Porsche moved to a Teroson sealant (typical supplier management - maybe cheaper?). The original Teroson formulation turned out to be insufficient, so Teroson provided an upgraded formulation . It is simply the cars produced from March - August that are effected, not cars produced earlier using the original sealant, and that would include cars destined for the US market.
Yea, the recall did not say "new sealant was introduced", only that "sealant was introduced". The word "new" changes the meaning. But even if they just switched to a new sealant, from the report it would seem like the old sealant was not good enough, or else they would not have needed to switch.
 

whitex

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The report also says "non-US cars", so if I were to guess, they were not recalled because the existing law framework (in whatever locale those batteries did leak) did not require the issuance of a recall. ?‍♂

And, to further the analogy, the original heisenbug was converted into a steady repro by the new feature.
So the conclusion is that the old solution was only leaking outside the US then, because there was no US cars reporting leaks yet?
 

whitex

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WasserGKuehlt

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Just for reference, my VIN shows up no-recall in the above link, but it falls into the NHTSA VIN range (and production date ).
The recall verifier has a VIN leak. (They’ll address it with a recall.)
 
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DougFrisk

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Just for reference, my VIN shows up no-recall in the above link, but it falls into the NHTSA VIN range (and production date ).
The APB2 recall currently applies to 900+ (probably undelivered) cars. There are 4777 total Taycans in the US with the potentially bad sealant per the notification. I suspect you will get a notice on or about October 31. Count yourself lucky that you have a car to drive.

When I called PCNA yesterday they said nothing would be done until November 1st. When I asked why they were holding my car hostage when they supposedly have the ability to test already and there's a 97% chance the car is fine they didn't have any answer.
 

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Yea, the recall did not say "new sealant was introduced", only that "sealant was introduced". The word "new" changes the meaning. But even if they just switched to a new sealant, from the report it would seem like the old sealant was not good enough, or else they would not have needed to switch.
My guess is that they added a new sealant vendor as part of their supply chain management activity. For all we know they now have multiple vendors providing battery sealant materials. That would make sense since most companies want multiple suppliers whenever possible.

It would not be uncommon for the new vendor to have a few hiccups along the way, and that is apparently what happened.
 


WasserGKuehlt

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Yea, the recall did not say "new sealant was introduced", only that "sealant was introduced". The word "new" changes the meaning. But even if they just switched to a new sealant, from the report it would seem like the old sealant was not good enough, or else they would not have needed to switch.
The recall said "Teroson sealant" was introduced, which has the same meaning as 'new', 'different' (ie it's a qualified noun). Also, these documents are polished and reviewed up and down the chain of several disciplines (engineering, PM, marketing etc.) I'm sure you've participated in security incidents, and so witnessed that process firsthand: you never volunteer unnecessary words or clarifications.

As for the reason of changing the sealant: I'm not inferring that the original wasn't good enough; on the contrary, they probably thought they could get away with less (or less expensive). After all, they did make 100k+ of these things.

So the conclusion is that the old solution was only leaking outside the US then, because there was no US cars reporting leaks yet?
Yes, correct. Back to the security incident analogy - first you try to placate the finder ("it's by design", "it's only in your geo", "you're holding it wrong"); if they prove their mettle (ie have proof), then you admit it, as narrowly as possible.

Seriously though, for Porsche/any manufacturer it's always a risk calculation: if it was bad, they'd act out of self-preservation; if they think (objectively, having debugged the failures) the risk is low per car, and low per total units sold, then they'll only go as far as the (local) law requires it.
 

summerlion

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This is all bit confusing to me.

So some number of cars were built using the bad Teroson sealant. Ok, fine.
Porsche is declining to deliver new cars that used the sealant, and eventually recalling already delivered cars that used it as well.
Those cars will all be tested to see if the battery is leaking. So far so good.
Any car with a detected leak will have the battery replaced with one using the improved sealant. Great.

However, my question is what happens to the estimated 97% of cars that don't need their batteries replaced now? The mitigation plan at nhtsa doesn't mention re-sealing the existing batteries or anything else. If there's a potential for (catastrophic) battery failure in the future I'd sure like to know about it ahead of time.
 

whitex

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My guess is that they added a new sealant vendor as part of their supply chain management activity. For all we know they now have multiple vendors providing battery sealant materials. That would make sense since most companies want multiple suppliers whenever possible.

It would not be uncommon for the new vendor to have a few hiccups along the way, and that is apparently what happened.
It makes sense, except for if the new sealant was introduced as part of supply chain management, why mention battery leaks prior to new sealant? If on the other hand new sealant was to address leaks, then shouldn't older car be recalled too?
 
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DougFrisk

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However, my question is what happens to the estimated 97% of cars that don't need their batteries replaced now? The mitigation plan at nhtsa doesn't mention re-sealing the existing batteries or anything else. If there's a potential for (catastrophic) battery failure in the future I'd sure like to know about it ahead of time.
I would expect nothing happens. For 97% of cars, the new sealant works fine and the cars will be returned to the owner with the recall satisfied after testing.
 
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DougFrisk

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It makes sense, except for if the new sealant was introduced as part of supply chain management, why mention battery leaks prior to new sealant? If on the other hand new sealant was to address leaks, then shouldn't older car be recalled too?
Here's what I suspect is happening. Cars built before the new sealant was introduced aren't being recalled because they were built to meet existing standards. Cars built between Sept 22 and May 23 with the defective sealant were built explicitly to be "air tight" and the sealant has failed to meet that standard to 100% effectiveness. The ones being recalled are the ones where Porsche and Audi can point at Henkels Automotive and say "Your sealant is failing to perform to the specifications you provided when applied per your instructions."

Porsche can make Henkels pay for the recall of these cars, much like a defective Takata airbag. Porsche would have to pay for the recall of any other cars and would rather wait until the car detects moisture in the battery and deal with it then.
 

whitex

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Seriously though, for Porsche/any manufacturer it's always a risk calculation: if it was bad, they'd act out of self-preservation; if they think (objectively, having debugged the failures) the risk is low per car, and low per total units sold, then they'll only go as far as the (local) law requires it.
So what you're saying is Porsche calculated the number of pre-MY23 batteries expected to leak within their battery warranty is low enough that their battery replacement and possible fire liability is cheaper than a recall. For MY23 the new sealant is bad enough that too many batteries will fail, causing larger cost than the recall cost. Did I get that right?
 

summerlion

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I would expect nothing happens. For 97% of cars, the new sealant works fine and the cars will be returned to the owner with the recall satisfied after testing.
I guess I hope this is the case. This seems like something they'd want to be super certain of, if only for the lawsuits that would result from them deciding to wait for actual failures of a known compromised component causing a fire somewhere.
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