Used hybrid car problems to look out for

Which used hybrids have known problems?

These hybrid and plug-in hybrid models have had safety recalls for faults in their battery, their hybrid system or other parts. The table lists them in no particular order, with the years the DVSA's records give for each.

From GOV.UK's vehicle recall service, checked by the year each car was made. Not every car of these models and years was affected, and this isn't every recall on them. The records don't show whether a car had the work done, so ask for proof. Contains public sector information licensed under the Open Government Licence v3.0.

Ford Kuga plug-in hybrid (from 2019)

The DVSA lists several recalls for the Kuga plug-in hybrid's high-voltage battery, some under the model name Kuga. A September 2020 recall says the pack can overheat and vent hot gas that can set parts of the car, or all of it, alight, and that owners shouldn't plug the car in and should drive only in Auto EV mode. Others cover contamination that can short circuit its cells (December 2020), and an internal fault or a badly welded part in one of its battery arrays (2022). Each of those fixes is a new battery. A November 2025 recall on Kugas built from 2019 to early 2026 updates the battery software, because some cells could short circuit; its title tells owners not to charge above 80%. In 2020 Ford paused sales of cars built before 26 June 2020 and said four fires were likely caused by overheating batteries, What Car? reported. What Car? said it didn't believe any injuries had been reported, and that Ford gave owners a free service plan and a fuel card. A 2024 recall, on cars built up to October 2022, updates software that could put the car into neutral.

BMW plug-in hybrids, including the 3 Series and X5 (2020–2021)

Two 2020 recalls cover the high-voltage battery on BMWs built in 2020, which only the plug-in hybrids, such as the 330e, have. They list the 3 Series and X5, and also the 2, 5 and 7 Series, X1, X2, X3 and i8. Particles left in the cells during production can cause a short circuit; the first recall's record says this was in very rare cases. BMW tests the battery and replaces affected cells or batteries. A 2022 recall for the X5 plug-in hybrid, made in 2020 and 2021, replaces battery cell modules for the same kind of fault.

Peugeot 3008 and 508 plug-in hybrids (2019–2023)

A 2024 recall replaces the high-voltage battery on some 3008 and 508 plug-in hybrids made from 2019 to 2021, for a fault that could cause a breakdown, a charging problem or overheating, and at worst a fire. Recalls in April 2023 reprogram the battery management software on cars made up to 2022, because overheating could lead to a fire. A September 2025 recall, on cars made from 2019 to 2022, tells owners to stop plug-in and eSave charging until the software is updated or the battery replaced. Another 2023 recall, on cars made up to January 2023, applies wax between the battery's reinforcing plate and its cover, where water could get in and wear through it.

Toyota Prius, Auris Hybrid and RAV4 plug-in hybrid

On the Prius made from late 2008 to 2015, the DVSA lists recalls for an inverter that can overheat, a hybrid system that may not go into its reduced-power safe mode or can shut down, and an EV fuse. The fixes are software updates and, for the fuse, a new one. The Auris Hybrid made from 2010 to 2018 has the safe-mode and shut-down recalls too. On the RAV4 plug-in hybrid made from 2020 to 2022, a damaged part in the DC-DC converter could overheat and risk a fire; Toyota replaces the converter. A 2023 recall, on cars made from late 2019 to 2021, updates software that could shut down the hybrid system when driving in EV mode in the cold.

Kia Niro Hybrid and Hyundai Ioniq (2016–2017)

Both have a recall for heat building up in the main power relays. Kia replaces the Niro Hybrid's relays and checks the relay assembly for heat damage; Hyundai replaces the Ioniq's relays and checks their holders. A second Ioniq recall, on a small number of cars, checks the power control unit for cracks that let coolant in and could shut down the high-voltage system. Two further Niro recalls cover a hydraulic clutch actuator fault that could cause an electrical short and a fire risk. Kia inspects the actuator and repairs or replaces it, and the later recall, on cars built up to 2022, also fits a lower-rated fuse.

Mitsubishi Outlander PHEV (2013–2016)

The Outlander PHEV recalls we list aren't in its hybrid system. On cars made from 2014 to 2016, the engine control unit's relay can overheat, so the engine may stall and not restart; Mitsubishi replaces the relay. On cars made from 2013 to 2016, water can rust the rear brake calipers so the parking brake may not hold.

Do hybrid batteries fail on used cars?

Toyota says it's rare, and the recalls above are for faults, not batteries wearing out. Toyota told Auto Express in 2020 that hybrid parts rarely need replacing under warranty and are designed to last the car's life. Toyota also adds a year of hybrid battery warranty with each service at a Toyota dealer, up to 15 years from registration, so a Toyota hybrid serviced by its dealers may still be covered. Other makers' battery warranties differ: check the handbook or ask a dealer.

Why are catalytic converters stolen from hybrids?

A hybrid uses its catalytic converter less, so its precious metals corrode less and are worth more to thieves, Fleet News reported in 2019. In one Cambridgeshire police count that year, most thefts were from the Toyota Prius, Toyota Auris and Honda Jazz. Honda fitted a tray under the Jazz from 2008 to make the converter harder to reach, and from 2015 put it in the engine bay. Toyota developed an anti-theft lock for its converters, called Catloc. On a used Prius or Auris, ask whether the converter has been replaced and whether a lock is fitted.

What should I check when buying a used hybrid?

Check the recalls, the servicing and the battery warranty, then drive it.

1. 1

   Check for recalls

   Enter the car's registration on GOV.UK's recall check to see safety recalls not yet checked or fixed. Without the registration, search by make, model and year.

2. 2

   Read the service history

   Look for every service on time. On a Toyota, dealer services also keep the hybrid battery warranty going.

3. 3

   Ask about the battery warranty

   Find out how much of the maker's battery cover is left, and what it needs to stay valid.

4. 4

   Start it and drive it

   Check that no warning lights stay on after start-up, and that it drives smoothly on electric power and on the engine.

5. 5

   On a plug-in, charge it

   Check that the charging cable is with the car and that the car charges.

6. 6

   Read the MOT history

   Look for repeat advisories, and mileage that fits the service stamps.

Our free check shows the car's colour, engine size and number plate from its official record, to match against the car and its logbook (V5C). CarCanny's full report shows every MOT test with its mileage and the tester's advisories, checks whether the mileage ever went down between MOT tests, and checks finance, write-off and stolen. The full report says whether the DVSA records an outstanding safety recall. GOV.UK's recall service lists each campaign by model and year.

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Written by

Maciej Kalka

Car enthusiast at CarCanny

Maciej is a researcher at vlayer, the company behind CarCanny, working on zero-knowledge proofs and applied cryptography. Before vlayer, Maciej was a doctoral researcher in physics at AGH University of Krakow.