Stellantis Expands U.S. Recall Over Brake Pedal Failure Risk in PHEV Models

Stellantis has announced an expanded safety recall in the United States involving nearly 6,000 additional plug-in hybrid vehicles, after identifying a defect that could cause the brake pedal to collapse during hard braking. The issue affects two compact PHEV crossovers sold under the Dodge and Alfa Romeo brands and raises renewed concerns about braking reliability in electrified vehicles.

Models and Production Years Affected

The recall applies specifically to the 2024 Dodge Hornet PHEV and the 2024 Alfa Romeo Tonale PHEV. According to Stellantis, 3,286 Dodge Hornet PHEVs and 2,688 Alfa Romeo Tonale PHEVs are included in this latest action.

Expansion of a Previous Recall

This is not a newly discovered problem, but rather an extension of a recall first issued in 2023. Last year, approximately 21,000 vehicles were recalled in the U.S. for the same brake pedal arm defect. With the addition of these newly identified vehicles, the total number of affected units has now reached around 27,000 nationwide.

Stellantis stated that further internal reviews and production data analysis revealed that more vehicles could be equipped with the same potentially faulty component, prompting the expansion.

Nature of the Brake Pedal Defect

At the center of the recall is a brake pedal arm that may fracture or collapse under heavy braking force. If this occurs, the driver could experience significantly reduced braking ability, increasing the risk of a collision.

A failed pedal arm does not completely eliminate braking, but it can make controlled stopping extremely difficult—particularly at higher speeds or in emergency situations.

Recommended Repair and Dealer Actions

To address the issue, Stellantis dealers will reinforce the brake pedal arm using a nut-and-bolt assembly. Importantly, the pedal arm will only be replaced if visible damage or breakage is detected during inspection.

All repairs will be carried out free of charge, and owners will receive formal recall notifications with instructions on how to schedule service.

What Drivers Should Do If the Pedal Fails

In the event of a brake pedal failure while driving, Stellantis advises drivers to pull up and hold the electronic parking brake button until the vehicle comes to a controlled stop. This feature is designed to gradually slow the vehicle rather than locking the wheels.

Additionally, the Automatic Emergency Braking (AEB) system is expected to engage if the system detects an imminent collision, provided it has not been manually disabled. While these backup systems offer some protection, the scenario underscores the seriousness of the defect.

Accidents and Injury Reports

Stellantis confirmed it is aware of one accident linked to this issue in Europe, though no injuries have been reported in any market related to the most recent recalls. In earlier global actions, the company recorded 15 related cases worldwide, which helped trigger the original investigation.

Shared Platform and Manufacturing Details

Both the Dodge Hornet PHEV and Alfa Romeo Tonale PHEV are built on the same Stellantis architecture and are manufactured at the Pomigliano assembly plant in Italy. The brake pedal arm in question was also produced in Italy, suggesting the defect may be tied to a specific supplier batch or manufacturing process.

Stellantis has not indicated whether additional models using similar components could be affected but said it continues to monitor the situation.

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