CALB Battery Defects Trigger Widespread GAC Aion S Failures

Systemic Battery Failures Reported in Fleet

Drivers reported severe battery issues including swelling, leakage, and ruptured cell casings. These defects cause unexpected power shutdowns while vehicles are in motion. Consumer platforms recorded 182 formal complaints in just two weeks.

The failures concentrate in vehicles that have driven between 150,000 km and 300,000 km. Investigations traced the problem directly to 177Ah lithium iron phosphate cells supplied by CALB. Analysts estimate a fault detection rate of nearly 5% across the affected fleet.

Manufacturing Errors Cause Deep Structural Risks

Industry experts say these battery failures point to systemic defects in the manufacturing process. Engineers identified improper electrolyte design and substandard assembly precision as key causes. The company also skipped rigorous long-term ageing tests during production.

Jiemian News cited analysts who warned that the defects pose immediate safety risks. Swelling cells can breach protective cases and trigger thermal instability. Both companies now face mounting public pressure to address the underlying design flaws.

Financial Toll Threatens Both Manufacturers

GAC Aion and CALB chose an extended warranty program instead of launching an official recall. Repair costs for more than 213,000 vehicles will create severe financial pressure. Similar battery disputes in China have cost companies over $340 million in settlements.

The potential repair bill comes at a difficult financial time for both firms. CALB reported a full-year profit of $308 million in 2025. Meanwhile, GAC Group expects a net loss of up to $662 million for the first half of the year.