U.S. Vehicle Recalls Surge as Millions of Drivers Face Hidden Safety Risks, New Analysis Finds

U.S. Vehicle Recalls Surge as Millions of Drivers Face Hidden Safety Risks, New Analysis Finds

A new nationwide analysis from DeMayo Law Offices reveals that vehicle safety issues remain a persistent and widespread threat to American drivers, with tens of millions of cars recalled every year due to dangerous defects, from faulty brakes and airbags to software glitches and battery-related fire risks. With 92% of U.S. households owning at least one vehicle and 283 million cars registered nationwide, the findings highlight a growing crisis affecting nearly every American family.

According to the study, U.S. automakers recalled approximately 29 million cars in 2022, 33.6 million in 2023, and 27.7 million in 2024. In just the first half of 2025, recalls have already surpassed 10.8 million vehicles, signaling that another year of widespread safety alerts is on track.

The States With the Most Cars Face the Highest Recall Burden

The report identifies the 10 states with the highest number of registered vehicles: California, Texas, Florida, Ohio, Pennsylvania, Illinois, Michigan, New York, Georgia, and North Carolina, as the regions where residents are disproportionately affected. California alone has over 30.4 million registered vehicles, while North Carolina features approximately 8.8 million, putting millions of drivers at high risk for recall-related hazards.

Applying national recall proportions to state-level registrations provides a stark estimate: North Carolina drivers could see more than 1.7 million vehicles affected by recalls every year.

The Defects Affecting Millions of Cars

Since 2020, the leading causes of automotive recalls show a blend of long-standing mechanical failures and emerging tech-driven risks.
The top problems include:

• Airbag defects, including faulty inflators and deployment failures

• Battery fires and charging issues, particularly affecting hybrid and electric models

• Engine and transmission failures, including sudden stalling

• Brake system failures

• Seatbelt malfunctions and airbag control unit defects

• Software issues, from driver-assist malfunction to infotainment system freezes

• Ignition switch failures and fuel system leaks

These flaws do more than inconvenience drivers; they create potential life-threatening situations on American roads.

Ford, GM, and Chrysler Lead the Nation in Recalls

Between 2020 and 2025, Ford issued the highest number of recalls, surpassing 17 million vehicles due to brake defects, transmission issues, fire risks, and persistent SUV safety problems.

General Motors, which includes Chevrolet, GMC, and Cadillac, follows closely behind with widespread recalls connected to engine defects, ignition problems, and electric vehicle fires.

Chrysler (Dodge, Jeep, Ram), Hyundai, Kia, Nissan, BMW, Volkswagen, Toyota, Honda, and Tesla all also appear prominently on the national recalls list.

From Recalls to Lawsuits: When Defects Lead to Legal Action

The study also identifies a strong overlap between brands with the most recalls and those facing the most class-action lawsuits. Companies like GM, Ford, Tesla, Hyundai/Kia, Toyota, Volkswagen, and Chrysler appear on both lists, showing a clear pattern: unresolved or recurring defects frequently escalate into legal battles.

Major lawsuits highlighted include:

• GM: 877,000+ trucks and SUVs with defective V8 engines

• Nissan/Infiniti: failures of the VC-Turbo engine affecting nearly half a million vehicles

• Hyundai/Kia: massive theft-related lawsuits due to missing immobilizers

• Ford: ongoing litigation over PowerShift transmission defects

Legal Protections for Drivers

The study also underscores how lemon laws, especially North Carolina’s New Motor Vehicles Warranties Act, protect consumers when repeated defects cannot be repaired. Class-action lawsuits offer broader recourse when problems span entire model lineups.

A Nationwide Call for Action

As modern cars become increasingly sophisticated, the study emphasizes the importance of both manufacturing integrity and rapid recall response. Millions of vehicles remain on the road with unaddressed “zombie recalls,” posing risks not only to drivers but also to other motorists.

The findings make one thing clear: with over 20 million cars expected to be recalled in 2025, vehicle safety remains a critical public-health issue. Manufacturers, regulators, and drivers must work together to ensure dangerous defects are identified, reported, and repaired as quickly as possible.