Jeep recalls 112,859 plug-in hybrids over casting sand in engines

Jeep is recalling 112,859 plug-in hybrid SUVs potentially containing leftover casting sand in their engines, reported Car and Driver, citing documents filed with the National Highway Traffic Safety Administration.

The recall includes 36,840 Cherokee 4xe models from the 2023 to 2025 model years and 76,019 Wrangler 4xe models from 2024 to 2025. The NHTSA filings revealed sand residue from the engine casting process may have remained in affected units, posing significant safety risks.

Leftover debris can cause "catastrophic" damage to internal engine components, potentially resulting in complete engine failure or vehicle fires. Owners may notice engine knocking sounds or a malfunction indicator lamp before failure occurs.

Jeep has begun dealer notifications, with owner notifications scheduled to commence at year-end. The company is still developing a remedy for the defect. Vehicle owners can verify recall eligibility through the NHTSA website.