Honda has filed a safety recall with the National Highway Traffic Safety Administration (NHTSA) affecting certain 2025 model year Honda CR-V e:FCEV vehicles due to a defect involving the fuel cell stack coolant system. The recall applies to vehicles produced between June 3, 2024, and March 26, 2025, and covers a total of 388 vehicles in the United States. Honda estimates that approximately 60 percent of the recalled vehicles may contain the defect.
The recall is documented in a Part 573 Safety Recall Report submitted by Honda to NHTSA and published on December 17, 2025. According to the filing, the issue involves the potential for fuel cell stack coolant to leak into the fuel cell stack case, which may result in an internal electrical short circuit. Honda has identified the condition as a safety-related defect due to the potential for loss of drive power while the vehicle is in operation.
The Honda CR-V e:FCEV is a fuel cell electric vehicle that uses compressed hydrogen to generate electricity onboard. Unlike battery electric vehicles, which store energy in high-voltage battery packs, fuel cell vehicles rely on a fuel cell stack to produce electrical energy through a chemical reaction between hydrogen and oxygen. The fuel cell stack operates within specific temperature and electrical insulation requirements, making coolant integrity and electrical isolation critical to proper function.
According to Honda’s recall documentation, the defect allows coolant used to regulate the temperature of the fuel cell stack to migrate into the stack case. If coolant enters this area, it can create an unintended electrical pathway between the fuel cell stack’s bipolar plate and the support-bar housing. This condition may result in a ground fault within the high-voltage system.
Honda states that an internal short circuit caused by this condition can lead to a loss of drive power. A sudden reduction or loss of propulsion increases the risk of a crash or injury, particularly if it occurs while the vehicle is in motion or in traffic. As a result, Honda determined that the condition constitutes a safety defect and initiated a recall.
The recall report identifies two separate root causes that may contribute to the coolant leak condition. The first relates to a manufacturing process change involving adhesive sealant used in the fuel cell stack assembly. Honda states that insufficient verification during this process change resulted in unfilled areas, shortened adhesive length, and reduced sealing performance at the fuel cell stack assembly end joint. These deficiencies compromised the ability of the joint to prevent coolant migration over time.
The second identified cause involves a supplier manufacturing process issue. Honda reports that the supplier failed to establish a deburring process for the O-ring groove of the wobble joint. Burrs left in the groove reduced sealing performance at that joint. Over time, this reduction in sealing effectiveness can allow fuel cell stack coolant to enter the stack case.
Honda explains that as coolant enters the fuel cell stack case, it may eventually create an electrical short between internal components. This short can trigger diagnostic trouble codes and warning messages, and in advanced stages may result in reduced power output or complete shutdown of fuel cell power generation.
The recall documentation outlines several warning messages that may be displayed to the driver as the condition progresses. These warnings are designed to alert the driver before a complete loss of drive power occurs. The first potential warning is a “Power System” message displayed in the instrument cluster when a high-voltage ground fault is detected, and diagnostic trouble code P0AA6 is stored.
As the condition worsens and coolant levels decrease, a second warning may appear stating, “FC insulating fluid low. See your dealer.” This message indicates that the fuel cell stack coolant, also referred to as insulating fluid, has dropped below normal levels in the reserve tank.
If air becomes mixed into the fuel cell stack coolant, the vehicle may display a “Power may be reduced. See your dealer” warning. At this stage, Honda states that fuel cell power output may be limited to approximately 20 kilowatts. This reduced power mode is intended to allow limited vehicle operation while prompting the driver to seek service.
In more advanced cases, when fuel cell stack coolant temperature rises, and power generation stops entirely, the vehicle may display a “Do not drive” or “Stop driving when safe” warning. These messages indicate that continued operation is no longer advised due to the shutdown of fuel cell power generation.
Honda’s recall remedy is the replacement of the entire fuel cell stack assembly. Registered owners of affected vehicles will be notified by mail and instructed to bring their vehicles to an authorized Honda dealer. Dealers will replace the fuel cell stack assembly with an improved component designed to address the identified sealing issues.
According to the recall report, the replacement fuel cell stack assembly differs from the recalled part in two key ways. The remedy component uses a rubber end unit seal instead of adhesive sealant, improving sealing consistency and durability. In addition, the wobble joints used in the replacement assembly have undergone a deburring process to eliminate burrs in the O-ring groove, restoring proper sealing performance.
Honda states that the recall repair will be performed at no cost to vehicle owners. This includes parts and labor associated with replacing the fuel cell stack assembly. The replacement procedure is intended to fully resolve the coolant leak condition and prevent recurrence.
The recall schedule outlined in the filing indicates that dealer notification is scheduled to begin and end on or about December 12, 2025. Owner notification is scheduled to begin and end on or about February 2, 2026. Owners will be notified using registration information on file and will be advised on how to schedule the recall repair.
Honda emphasizes that the recall population was determined using manufacturing records, and the production range includes all vehicles that could potentially experience the condition. Not every vehicle within the production range is expected to exhibit the defect, but Honda included all potentially affected vehicles to ensure full coverage.
Fuel cell electric vehicles remain a low-volume segment of the U.S. automotive market, and the CR-V e:FCEV represents one of Honda’s limited hydrogen-powered offerings. As with other advanced propulsion systems, fuel cell vehicles rely on precise manufacturing processes and component integrity to maintain safety and performance. Issues involving coolant sealing and electrical insulation are particularly significant due to the interaction between liquids and high-voltage components.
Honda’s recall filing does not indicate any reported crashes or injuries associated with the defect at the time of submission. The recall action appears to be preventative in nature, addressing the risk before widespread field incidents occur. Federal regulations require manufacturers to initiate recalls when a defect related to motor vehicle safety is identified, regardless of whether injuries have been reported.
Owners of 2025 Honda CR-V e:FCEV vehicles can verify whether their vehicle is included in the recall by checking their vehicle identification number through Honda customer service or the NHTSA recall lookup tool. Honda encourages owners to follow recall instructions promptly once notified to ensure the continued safe operation of their vehicles.
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