A new study shows that the number of software-related automotive recalls has risen year on year. This is based on data from the US Department of Transportation. The data set shows that Chrysler, Ford, and Mercedes are the manufacturers who had the most recalls overall.
As cars become increasingly computerised, some issues can be fixed via over-the-air (OTA) software updates. Though these updates are still categorised as a ‘recall’, they eliminate the need for a dealership visit.
To investigate the rise of software-related recalls in the automotive industry, DeMayo Law conducted a study using recall data taken from the National Highway Traffic Safety Administration (NHTSA). The results have been shared with Digital Journal.
The DeMayo Law team analysed recall data to understand the growing role of software in automotive recalls, calculating the percentage of software recalls compared to hardware recalls for each year. Their findings identified which car manufacturers have the highest percentage of software-related issues, and determined which components were most often affected.
The data collected spans from 2014 to 2024, categorising all recalls into software and hardware fixes, revealing the year-over-year changes in recall types.
Table 1: The Percentage of Software-related Recalls, by Year
| Year | All Recalls | Software Recalls | Percent of All Recalls | Change Year On Year |
| 2014 | 277 | 34 | 12.27% | N/A |
| 2015 | 279 | 42 | 15.05% | +22.64% |
| 2016 | 302 | 37 | 12.25% | -18.61% |
| 2017 | 296 | 39 | 13.18% | +7.54% |
| 2018 | 315 | 39 | 12.38% | -6.03% |
| 2019 | 313 | 40 | 12.78% | +3.22% |
| 2020 | 303 | 44 | 14.52% | +13.63% |
| 2021 | 381 | 61 | 16.01% | +10.25% |
| 2022 | 348 | 76 | 21.84% | +36.40% |
| 2023 | 356 | 82 | 23.03% | +5.47% |
| 2024 | 233 | 51 | 21.89% | -4.97% |
Table 2: The Percentage of Hardware-related Recalls, by Year
| Year | All Recalls | Hardware Recalls | Percent of All Recalls | Change Year On Year |
| 2014 | 277 | 243 | 87.73% | N/A |
| 2015 | 279 | 237 | 84.95% | -3.17% |
| 2016 | 302 | 265 | 87.75% | +3.30% |
| 2017 | 296 | 257 | 86.82% | -1.05% |
| 2018 | 315 | 276 | 87.62% | +0.92% |
| 2019 | 313 | 273 | 87.22% | -0.45% |
| 2020 | 303 | 259 | 85.48% | -2.00% |
| 2021 | 381 | 320 | 83.99% | -1.74% |
| 2022 | 348 | 272 | 78.16% | -6.94% |
| 2023 | 356 | 274 | 76.97% | -1.53% |
| 2024 | 233 | 182 | 78.11% | +1.49% |
The total number of recalls has been steadily increasing over the past decade, with a large spike to 381 recalls in 2021. The analysed data only goes as far as April 2024, so the trend might continue upward as the year goes on.
Generally, the number of software recalls have been trending upward. The number of hardware recalls has remained relatively similar, aside from a spike to 320 in 2021. The percentage of hardware recalls has been trending downward year on year, while the percentage of software recalls has been going upward.
The percentage of software recalls saw a spike from 16 percent to 21.84 percent in 2022, and the percentage has remained in the 20s for each subsequent year. The percentage had always been in the mid-to-low teens for earlier years, so this is a significant difference.
The growing number of software-related recalls reflects changes in how cars are manufactured. The software and computer elements of cars have become much more important and integrated as cars become more advanced, while the number of faults and problems with these systems has increased as more software is introduced.
Which Manufacturers Had The Most Recalls?
The study also identified which car manufacturers have the highest percentage of software-related recalls, highlighting leaders in this technological shift.
Table 3: Software Recalls By Manufacturer
| Rank | Manufacturer | No. of Occurences | Percentage of All Software Recalls |
| 1 | Chrysler (FCA US, LLC) | 82 | 15.05% |
| 2 | Ford Motor Company | 66 | 12.11% |
| 3 | Mercedes-Benz USA, LLC | 60 | 11.01% |
| 4 | General Motors, LLC | 49 | 8.99% |
| 5 | Jaguar Land Rover North America, LLC | 42 | 7.71% |
| 6 | Volkswagen Group of America, Inc. | 39 | 7.16% |
| 7 | BMW of North America, LLC | 37 | 6.79% |
| 8 | Tesla, Inc. | 26 | 4.77% |
| 9 | Hyundai Motor America | 25 | 4.59% |
| 9 | Kia America, Inc. | 25 | 4.59% |
Chrysler has been identified as the manufacturer with the highest percentage of software recalls, at 15.05 percent. Ford comes in second with 12.11 percent, a. Mercedes was in a close third with 11.01 percent. General Motors, which produces brands like Chevrolet, Buick, and Cadillac, was in fourth with 49 recalls. Tesla, Hyundai and Kia all had a very similar number and percentage of recalls. Tesla had 26 recalls, while Hyundai and Kia had 25.
Recalls By Component
The study also examined which components were most frequently subject to software and hardware recalls, providing insights into evolving automotive technology trends and identifying key areas for manufacturer and regulator focus.
Table 3: Top 5 Components Affected by Software and Hardware Recalls (2014-2024)
| Hardware | |||
| Rank | Component | No. Of Occurrences | Percentage |
| 1 | AIR BAGS | 524 | 18.33% |
| 2 | ELECTRICAL SYSTEM | 296 | 10.36% |
| 3 | POWERTRAIN | 228 | 7.98% |
| 4 | FUEL SYSTEM, GASOLINE | 196 | 6.86% |
| 5 | SEAT BELTS | 177 | 6.19% |
| Software | |||
| Rank | Component | No. of Occurrences | Percentage |
| 1 | ELECTRICAL SYSTEM | 170 | 31.19% |
| 2 | BACK OVER PREVENTION | 73 | 13.39% |
| 3 | AIR BAGS | 52 | 9.54% |
| 4 | POWERTRAIN | 44 | 8.07% |
| 5 | EXTERIOR LIGHTING | 30 | 5.50% |
For software recalls, electrical systems are the most common component affected, accounting for 31.19 percent of all software-related recalls. Interestingly, electrical systems are also the second most common component in hardware recalls (10.36 percent).
Airbags are the most frequent component in hardware recalls (18.33 percent) and the third most common in software recalls (9.54 percent). Back over prevention appears in the top 5 for software recalls (13.39 percent) but not for hardware, likely reflecting the increasing integration of advanced driver assistance systems (ADAS) in modern vehicles.
Powertrain issues feature prominently in both hardware (7.98 percent) and software (8.07 percent) recalls. This indicates that as powertrain systems become more computerized, software issues are becoming as common as mechanical problems.
