The least safe EVs you can buy in 2025
Electric vehicles are generally among the safest vehicles on the road, with low centers of gravity, advanced driver-assist features, and strong crash structures. But not every EV meets those expectations. Some models fall short in crash tests, others suffer from dangerous recalls, and a few are plagued by software or battery issues that raise serious safety concerns.
This slideshow highlights five EVs currently on sale in the U.S. that stand out for the wrong reasons. These models have notable safety shortcomings — from poor crash protection to serious fire risks — that buyers should be aware of before signing on the dotted line.
Ford F-150 Lightning: Poor rear-seat protection and fire concerns
The Ford F-150 Lightning offers impressive capability, but its safety record isn’t spotless. The Insurance Institute for Highway Safety (IIHS) rated the Lightning “Poor” in its updated moderate overlap front crash test, citing a high risk of head, neck, and chest injuries for a rear-seat passenger. The test also found that the lap belt slipped dangerously from the pelvis to the abdomen, increasing the risk of internal injuries. That result keeps the Lightning from earning a Top Safety Pick designation and highlights a serious occupant protection gap.
Ford has also dealt with significant safety recalls on the Lightning. In early 2023, production was halted after a truck’s battery pack caught fire while parked, an incident that spread to two nearby vehicles. The company traced the problem to a manufacturing defect and issued a recall to replace affected battery components. Other recalls have addressed a loose suspension ball joint that could cause a sudden loss of steering — linked to at least one crash — and a software issue that could disable power brake assist.
While Ford has implemented fixes, these incidents show that even a high-profile EV can have real safety shortcomings. The Lightning remains capable and innovative, but owners should ensure all recall work is completed — and rear passengers may want to think twice before riding along.
Nissan Ariya: Marginal crash test results and sudden power loss
The Nissan Ariya is one of the newest electric crossovers on the market, but it stumbled in a key safety evaluation. IIHS rated the Ariya “Marginal” in the moderate overlap front crash test due to poor rear-seat protection. Crash dummies showed a high risk of chest injuries in a collision, and excessive forward movement suggested the seat belt system wasn’t restraining occupants as effectively as it should. That result kept the Ariya from earning any IIHS safety awards, putting it behind many competitors.
Nissan has also recalled the Ariya for a potentially serious software issue affecting the power inverter. A defect could incorrectly detect a short circuit and shut down the EV’s drive system without warning, causing the vehicle to lose propulsion while moving. Another bulletin flagged a possible seal issue in the motor housing that could allow oil to leak into the motor and cause failures over time.
No significant fire risks have been reported, but these drivetrain problems could create hazardous situations on the road. While the Ariya’s front crash performance and driver-assistance features are solid, its rear-passenger safety and reliability issues hold it back from being a top safety performer.
Chevrolet Bolt EV/EUV: Good crash safety overshadowed by fire risk
On paper, the Chevrolet Bolt EV and Bolt EUV perform well in crash testing, with five-star overall ratings from NHTSA and “Good” marks from IIHS. Unfortunately, the Bolt’s reputation has been overshadowed by one of the largest and most serious EV safety recalls ever. A manufacturing defect in its LG-supplied battery cells could trigger thermal runaway fires even while the vehicle was parked and charging. The recall ultimately covered every Bolt built from 2017 to 2022 — about 140,000 vehicles — and owners were advised to park outside and avoid overnight charging until fixes were installed.
The Bolt’s fire issues didn’t end there. Another recall affected roughly 140,000 units due to a fire risk caused by the seat-belt pretensioner system. During a crash, the system could ignite nearby carpeting, leading to a fire inside the cabin after impact. Chevrolet addressed the issue by adding protective shields, but the fact that two separate fire risks emerged raised serious concerns.
These problems led GM to replace defective battery modules across the Bolt lineup, a costly but necessary fix. Post-recall Bolts are significantly safer, but the model’s fire-related history underscores the importance of proper recall work — and why the Bolt belongs on any list of EVs with notable safety concerns.
Jaguar I-Pace: Repeated battery fires and buybacks
The Jaguar I-Pace debuted as one of the first luxury electric SUVs, earning five stars in Euro NCAP crash tests. But in the years since, its battery safety record has raised alarms. Between 2023 and 2024, Jaguar issued five separate recalls for overheating high-voltage battery packs that could catch fire. In several cases, I-Pace vehicles caught fire even after receiving software updates intended to monitor and prevent overheating.
The situation became so serious that Jaguar ultimately offered to buy back nearly 3,000 vehicles from the 2019 model year because a permanent fix couldn’t be guaranteed. For newer models, Jaguar limited the maximum state of charge to about 80% and urged owners to park outside as a precaution. The root cause appears to be similar to the defect that plagued the Chevrolet Bolt, involving LG-supplied battery cells that can short-circuit internally.
While no injuries have been linked to these incidents, a vehicle that can spontaneously ignite poses a significant safety risk. The I-Pace’s crash performance and driver-assistance tech are otherwise strong, but its unresolved battery issues keep it from being considered one of the safer EVs on the market.
VinFast VF 8: Software problems and airbag failures
VinFast’s VF 8 is a newcomer to the U.S. EV market, but its launch has been marred by a series of safety problems. The most serious involved the Lane Keeping Assist system, which could suddenly jerk the steering wheel and pull the car toward barriers, even resisting driver input. NHTSA received multiple complaints and opened an investigation, leading to a recall of every VF 8 sold in the U.S. — more than 6,000 vehicles — for a software fix.
Other safety recalls have targeted the VF 8’s airbag systems. One recall addressed a “center airbag” that could deploy incorrectly and strike the driver’s arm during a side impact. Another covered faulty igniters that could prevent airbags from deploying at all in a crash. A separate issue caused the instrument cluster and warning display to go blank while driving, leaving drivers without critical safety information.
VinFast has issued software patches and hardware fixes, but the sheer number and severity of recalls raise concerns about the VF 8’s readiness for U.S. roads. While no major battery issues have been reported, the brand’s safety track record is still being established — and until these issues are fully resolved, caution is warranted.
What these five EVs teach us about safety
Most electric vehicles are exceptionally safe, often outperforming gasoline-powered cars in crash tests and safety features. But the five models highlighted here — the Ford F-150 Lightning, Nissan Ariya, Chevrolet Bolt EV/EUV, Jaguar I-Pace, and VinFast VF 8 — show that even EVs can fall short in crucial areas. Whether it’s poor crash protection, sudden power loss, fire hazards, or dangerous software bugs, each of these vehicles has significant safety caveats that shoppers should understand.
In many cases, recalls and software updates have mitigated the risks, and owners who stay current with repairs can reduce their exposure to potential hazards. Still, these models underscore the importance of digging deeper than star ratings and spec sheets when evaluating a new EV. Safety isn’t just about crash performance — it’s also about reliability, software, and how a vehicle behaves in the real world.
Sources
- Insurance Institute for Highway Safety (IIHS). “Moderate Overlap 2.0 Crash Test Results for 2025 EVs.” Results include: Ford F-150 Lightning – Poor; Nissan Ariya – Marginal; Tesla Model 3 – Acceptable; others – Good.
- Autoevolution. “Nissan Drops Ariya from U.S. Lineup After Underperforming in Crash Test.” Details Ariya’s marginal crash rating and Nissan’s response.
- Repairer Driven News. “Four Out of Seven 2025 EVs Earn Good Ratings in IIHS Crash Test.” Provides test details and rear-seat injury risk findings for F-150 Lightning.
- InsideEVs. “Major Suspension and Steering Issue Prompts F-150 Lightning Recall.” Covers recall of ~11,922 trucks for loose ball joint nut leading to loss of steering control.
- Michigan Public Radio / Associated Press. “Ford Suspends Production of Electric F-150 After Battery Fire.” Reports on 2023 production halt and root cause of battery defect.
- National Highway Traffic Safety Administration (NHTSA). “GM Expands Recall, All Chevrolet Bolt Vehicles Now Recalled.” Covers fire risk and guidance to park vehicles outside and limit charging.
- Emkay Fleet. “GM Recalls 140K Chevrolet Bolt EVs.” Describes seat-belt pretensioner-related fire recall.
- Road & Track. “Jaguar Is Buying Back Almost 3,000 I-Pace EVs Due to Fire Risk.” Documents repeated battery recalls, overheating issues, and buyback decision.
- Carscoops. “VinFast Owner Says Their EV Took Over Steering and Nearly Hit a Wall.” Reports on lane-keeping assist issue, NHTSA investigation, and recall of all VF 8 vehicles.
- Cars.com Recalls. “VinFast VF 8 Recalls.” Lists multiple recalls for airbag deployment issues, faulty igniters, and display screen blanking.
- Transport Canada Recall #2024309. “Nissan Ariya Drive Motor Seal Issue.” Notes potential oil ingress in motor leading to failure.
