RA-63-1832 – 12V Battery PSS Fusebox – 2021-2024 Aston Martin DBX

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ASTON MARTIN AFTERSALES
05 April, 2024 Page 1 of 3
RECALL ACTION
Reference number:
RA-63-1832
Issued: 05 April, 2024
Subject:
12V Battery PSS Fusebox
Model:
DBX (all models)
VIN Range:
Refer to the separately published list of affected Vehicle Identification Numbers (VINs)
Applicable to:
All Markets (except China)
Distribute to:
Aftersales Manager
Executive Manager
Service Manager
Sales Manager
Warranty Staff
Technician(s)
Parts Staff
Attached Documents:
•Copy of the Owner Notification letter for vehicles in RA-63-1832
•Copy of the Change of Keeper or Address form
Reason for this Recall Action
Aston Martin has determined that a defect which relates to motor vehicle safety may exist on a number of DBX vehicles built between May 2020 and September 2022.
On the affected vehicles, it is possible that three M8 fixings in the 12V battery fusebox may work loose.
To correct this problem, do the Workshop Procedure given in this document to install the necessary new washer, split washer and flat M8 nut
The full list of VINs for the affected vehicles are attached to this Recall Action document.
PLEASE DO A CHECK OF ALL VEHICLES THAT ARE IN THE AFFECTED VIN LIST
Communications
The customer letter and the “Change of Keeper or Address” form are uploaded to Technical Hub.
When the Owner calls to make an appointment, briefly describe the repair which will be done to the Owner’s vehicle and explain the reason for this work. Tell the owner that the repair will be done at no cost to them.
RECALL ACTION RA-63-1832
05 April, 2024 Page 2 of 3
Workshop Procedure
1.
Disconnect the vehicle 12V battery (refer to Workshop Manual Procedure 63.01.AK).
2.
Remove the cover for the fusebox (refer to Workshop Manual procedure 63.01.AR).
3.
Remove the M8 fixings that follow (refer to Figure 1):
1. ‘Dirty’ feed – Starter motor, alternator, and front jumpstart point (pyrotechnic cut off switch)
2. Rear cabin fusebox (200A Fuse)
3. ‘Clean’ feed to engine fusebox (250A Fuse)
Figure 1
4.
Do a check for any debris or signs of high temperature on the fusebox and cable eyelets.
5.
Install the washer, split washer and flat M8 nut to each affected stud in the fusebox.
6.
Torque the new fixings to 12 Nm.
7.
Install the cover for the fusebox (refer to Workshop Manual Procedure 63.01.AR).
8.
Install the liner for the spare wheel well (refer to Workshop Manual Procedure 30.03.PW).
9.
Connect the vehicle 12V battery (refer to Workshop Manual Procedure 63.01.AK).
2
3
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RECALL ACTION RA-63-1832
05 April, 2024 Page 3 of 3
Warranty Data
Procedure and Labour Time
Tier A
Description
Labour Time
Examine for debris and thermal damage, and install three flat washers, spring washers and flat M8 nuts. Thermal Damage not found.
0.7 Hour
Tier B
Description
Labour Time
Examine for debris and thermal damage, and install three flat washers, spring washers and flat M8 nuts. Thermal damage found*.
0.7 Hour
*Please submit a manual warranty claim for parts replaced due to thermal damage.
Part Data
Description
Part Number
Quantity
WASHER SPRING-M8 -RECTANGULAR
709096
3
WASHER-PLAIN-M8
709097
3
NUT-M8
709098
3
To contact Aston Martin for further information about this document, please refer to the “Contact Us” page in Technical Hub.
Copy of the Owner Notification Letter
RA-63-1832 Customer Letter FED – Copy Page 1 of 2
[Date DD Month, YYYY]
[Customer Name]
[Customer Address 1]
[Customer Address 2]
[Customer City/County]
[Customer Country]
IMPORTANT SAFETY RECALL NOTICE
NHTSA Recall [NHTSA Ref]
This notice applies to your vehicle: [INSERT VIN]
Dear [Customer]
Safety Recall Action RA-63-1832 – DBX 12V Battery Fusebox
REASON FOR THIS RECALL ACTION
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Aston Martin has decided that a defect which relates to motor vehicle safety may exist in certain vehicles that were manufactured from May 2020 through September 2023.
Aston Martin has not received any report of an accident or injury caused by this defect. As a precaution, however, we ask that you contact your dealer for assistance with this important safety action.
On the affected vehicles, it is possible that the fixings for the fuse box cables are not correctly torqued.
This could cause the cables to become loose, and (if undetected) could cause the vehicle to lose electrical power or heat damage to the fuse box. Loss of electrical power could result in the engine stalling or loss of headlights, power assisted steering, or other vehicle functions. These could increase the risk of crash. Heat damage to the fuse box could cause smoke in the boot or an unpleasant odour.
A loose fuse box cable may cause a battery warning light to display on the instrument cluster.
The repair, if needed, involves the simple and fast replacement of a new washer, split washer, and flat nut to each affected stud in the fuse box.
The models affected are:
• 2020 – 2023 DBX
• 2022 – 2023 DBX707
Copy of the Owner Notification Letter
RA-63-1832 Customer Letter FED – Copy Page 2 of 2
WHAT WE WILL DO
Aston Martin will inspect and if necessary, repair all affected parts. This action will be done at no cost to yourself.
WHAT YOU SHOULD DO
Please contact your Aston Martin dealer as soon as possible to arrange a date for the repair. They will be able to fully explain why this Recall Action is necessary. Instructions for making this correction have been sent to your dealer. The labor time necessary to complete this service correction is a maximum of one hour. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.
Your Aston Martin dealer is best equipped to obtain parts and provide the service to make sure that your vehicle is corrected as promptly as possible. If, however you take your vehicle to your dealer on the agreed service date and they do not remedy this condition on that date, or within three days, we recommend that you contact Aston Martin Customer Service by calling 1-886-276-6661
If after contacting your dealer and Aston Martin Customer Services, you are still not able to have the safety defect remedied without charge and within a reasonable time, you may wish to write to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590 or call 1-888-327-4236 (TTY: 1-800-275-9171) or go to http://www.nhtsa.gov.
IF YOU NO LONGER OWN THE VEHICLE
If you have sold or traded your vehicle, please tell us by completing the enclosed Change of Keeper form and returning it to us.
We are sorry to cause inconvenience with this Recall Action. However, this action has been taken in the interest of your safety and continued satisfaction with our products.
Yours sincerely
[Dealer’s Representative] [Representative’s Job Title] [Dealer Name]
Copy of the Change of Ownership form
Please return this form by mail to: Client Services, Aston Martin Lagonda Ltd, Banbury Road, Gaydon, Warwick, CV35
0DB, England.
Or, if you prefer, you can scan and email it to [email protected].
THANK YOU FOR YOUR CO-OPERATION
Recall Action RA-63-1832
Models: DBX
Subject: 12V Battery PSS Fusebox
CHANGE OF KEEPER OR ADDRESS
VEHICLE IDENTIFICATION NUMBER
(VIN)
REGISTRATION NUMBER
(where known)
S C F
Please tick the applicable box:
I do not own/operate this vehicle now. The vehicle has been:
Stolen (1)
Scrapped (2)
Sold or Transferred to a new owner (3)
Part exchanged at an Aston Martin Lagonda Dealer (4)
Part exchanged at a non-Aston Martin Lagonda Dealer (5)
Declared an insurance total-loss (6)
Permanently exported to another country (7)
Returned to a lease company (8)
Sold at auction (9)
The address you have used is incorrect (10)
If you have ticked a box from (3) to (10), please record the latest known keeper information below:
Business Name
Title
First Name
Last Name
Address Line 1
Address Line 2
Town
County
Postal/Zip Code
Country
Signature: Date:

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-255
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Aston Martin The Americas APR 05, 2024 NHTSA Recall No. : 24V-255 Manufacturer Recall No. : RA-63-1832 Manufacturer Information :
Manufacturer Name : Aston Martin The Americas Address : Banbury Road
Gaydon Warwick, United Kingdom 00 CV35 0DB
Company phone : 999
Population :
Number of potentially involved : 2,902 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2021-2024 Aston Martin DBX Vehicle Type : LIGHT VEHICLES Body Style : SUV Power Train : GAS
Descriptive Information : All DBX vehicles built between 7th May 2020 and 15th September 2023.
Production Dates : MAY 07, 2020 – SEP 15, 2023
VIN Range 1 : Begin : SCFVUJAW3MTV00145 End : SD7VUJBW2RTV10377 Not sequential Description of Defect :
Description of the Defect : The battery fusebox distributes electrical power to the vehicle using cables which are attached to threaded studs using eyelets. The roles of the cables are:
1. Input feed from the power sources – Starter motor, alternator, and front jumpstart point
2. Output feed to rear cabin fusebox (200A Fuse)
3. Output feed to engine fusebox (250A Fuse)
These cables are attached to the fusebox using threaded studs and fixings. Initial build of the vehicles uses a serrated M8 nut torqued to 9 Nm.
Customers have reported that a battery warning message appeared on the instrument cluster, and the vehicle may have stalled or does not start.
Investigation by the dealer finds that the nuts which retain the cable eyelets on the battery fusebox are loose. In some cases, there is localised thermal damage which is contained to the plastic housing of the battery fusebox. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Loose nuts could cause the cables to become loose, and (if undetected) could Part 573 Safety Recall Report 24V-255 Page 2 Description of the Safety Risk : cause the vehicle to lose electrical power or heat damage to the fuse box. Loss of electrical power could result in the engine stalling or loss of headlights,
power assisted steering, or other vehicle functions. These could increase the risk of crash. Localised heat damage to the plastic housing of the battery fuse box could cause smoke in the boot or an unpleasant odour. Aston Martin is not aware of any injuries or road traffic accidents associated with this concern.
Description of the Cause : A sub-assembly station is used to install the cables to the battery fusebox, and to apply torque to the nuts on the threaded studs. The assembled battery fusebox and cables are manually carried to the vehicle for assembly on the production line.
The combination of a serrated nut and manual handling may result in the torque being reduced due to a ‘ratcheting’ action, and therefore the nuts may become loose during service of the vehicle.
If the nut becomes loose, there may be insufficient surface contact between the cable eyelet and the battery fusebox. This increases the resistance in the circuit leading to overheating and damage to the plastic housing. Identification of Any Warning
that can Occur : A warning message may illuminate on the instrument panel. The warning type can vary depending on which system is affected by loss of electrical power.
The driver may be able to identify an unpleasant odour in the cabin. Involved Components : Component Name 1 : Nut M8 Component Description : Nut M8 Component Part Number : 709098 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-255 Page 3 Chronology :
• 15th June 2022 – Aston Martin’s Technical Review Group (TRG) convened to investigate reports of DBX battery fusebox with localised heat distortion to the fusebox caused by loose fixings to the 250A fuse, contained to the plastic housing of the battery fusebox.
• 17th January 2023 – Containment introduced to fit flat nut, spring washer and flat washer to the 250A fuse with 12Nm torque.
• 30th May 2023 – Aston Martin launched an inspection of 300 vehicles to understand whether loose fixings were present.
• 17th August 2023 – A market incident involving loose fixings is reported affecting the 400A fuse.
• 22nd September 2023 – Countermeasure introduced to fit flat nut, spring washer and flat washer to the 200A fuse and input feed fuses with 12Nm torque.
• The Company’s Technical Review Group (TRG) met regularly throughout the investigation.
• The Company’s Critical Concerns Review Group (CCRG) met on 27th and 28th September 2023 and recommended the matter should be reviewed by the Recall Committee.
• Further investigation and confirmation of Permanent Corrective Action (PCA) have taken place through torque audit checks.
• The Recall Committee convened on 03/04/2024 and determined that:
a) a potential defect could occur in the relevant vehicle population.
b) this defect could lead to a potential safety risk; and
c) a voluntary safety recall of all affected vehicles should be implemented. Description of Remedy :
Description of Remedy Program : Aston Martin will remove the three affected cables from the threaded
studs and check the fuses and cable for any damage. If any damage is discovered the affected parts will be replaced.
The serrated nuts will be replaced with a flat nut, a flat washer and a spring washer. The torque will be increased to 12Nm. Owners will be notified to take their vehicle to an Aston Martin Dealer. The repair procedure will take under 1 hour to complete, at no cost to the owner. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : The remedy components use a flat nut, a flat washer, and a spring washer. The torque is increased from 9Nm to 12Nm. This is to prevent the ‘ratcheting’ affect that may occur if the cable is moved.
The flat washer and increased torque was used in production from the 16th September 2023 Recall Schedule :
Description of Recall Schedule : It is Aston Martin’s intention to notify all customers listed in table in
573.6(c) (2) above. Aston Martin will provide copies of the notification schedule, including mail dates for the owner letter, when available. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-255
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Aston Martin will provide a representative copy of the dealer bulletin, when available.
Planned Dealer Notification Date : APR 05, 2024 – OCT 07, 2024 Planned Owner Notification Date : APR 22, 2024 – NR
* NR – Not Reported

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