2019 Alfa Romeo Stelvio

1. COMPONENT FAILED & INSPECTION: The transmission ground strap (uninsulated, bare braided copper cable) completely corroded/severed from environmental decay. This open ground circuit forced high engine-cranking currents into secondary low-voltage paths, causing an extreme thermal surge that melted and shorted out the main engine compartment wiring harness. Both failed components are preserved by the owner and are available for forensic inspection upon request. 2. SAFETY RISK: This manufacturing flaw causes a severe thermal fire hazard and an instantaneous, catastrophic loss of all vehicle propulsion, power steering, braking assist, and lighting systems while operating on public roadways. This abrupt deactivation threatens occupant safety and surrounding traffic by risking high-speed highway collisions or engine bay fires without warning. 3. CONFIRMATION: The exact failure cascade was formally diagnosed, itemized, and verified by Maranello Alfa Romeo of [XXX] ([XXX]) under a repair estimate of $7,203.10. 4. INSPECTIONS: Formally inspected by factory-certified technicians at the local authorized dealership center. No insurance, police, or outside authority investigations have occurred yet, as the car was towed immediately to avoid an active open highway fire. 5. SYMPTOMS & WARNINGS: There were absolutely no warning lamps, messages, check engine lights, or symptoms prior to the incident. Failure occurred instantly on XXX. The vulnerability was hidden from plain sight until the primary ground pathway severed completely during engine startup. 6. MANUFACTURER KNOWLEDGE: Alfa Romeo engineering has recognized this danger on 2017-early 2023 models, releasing a redesigned, fully sheathed/insulated ground cable (Part No. 68648999AA) to prevent this environmental decay. The consumer was never proactively notified of this critical safety vulnerability INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

There were no warning lights prior to driving and the vehicle stopping on the highway 2 times. Now the warning lights is constant and referencing the recall from 09/2025. Still no remedy for the recall. Mopar and the Alfa Romeo dealership have not contacted me regarding fixing the problem. A class action lawsuit needs to be filed

My car stopped and would not turn back on while in the middle lane of a busy highway. We were stopped on the highway >20min until police arrived to block the lanes so we could safely exit the vehicle and a tow truck could safely retrieve it. The ground strap underneath the vehicle that grounds the main engine harness was broken. As a result the electrical short resulted in burning/melting of several spots on the harness. There was no warning ahead of time and I’ve learned that this is a known issue. We are very lucky that this did not lead to a crash, injury or death.

The contact owns a 2019 Alfa Romeo Stelvio. The contact stated that the vehicle was unintendedly stopping and starting. While driving at 15 MPH, the vehicle shut off. The vehicle was jump-started. The driver was able to continue driving. The contact had the battery replaced at an independent mechanic. The vehicle was taken to the local dealer, who confirmed that the battery was not operating properly. The ABW warning light was illuminated. While pulling into the fuel station, the vehicle shut off. The vehicle was jump-started, and the contact drove to the local dealer, but the vehicle was not diagnosed or repaired. The contact became aware of NHTSA Campaign Number: 25V586000 (Fuel System, Gasoline). The manufacturer was not contacted. The failure mileage was approximately 69,000.

A corroded faulty ground strap under the car, which is connected to the transmission caused the engine wiring harness to overload a smaller ground wire in the wheel well, then continued to melt other sections of the main engine wiring harness when trying to start the car. This is only a $200 part, but caused $6k+ of damages calling for a labor intensive job of replacing the entire engine wiring harness. The manufacturer does not provide any information on this to the owner as a maintenance issue or something to keep an eye on to prevent this issue. It's obviously a defect.

I PURCHASED MY CAR IN JAN. 2020. ON JUNE 21, 2020, I AWOKE TO MY ALARM GOING OFF. I TRIED TO USE MY KEY FOB TO TURN THAT ALARM OFF AND IT DID. NOT WORK. THE ALARM STOPPED AND I HAD TO USE THE HARD KEY TO ENTER MY CAR. THE CAR WOULD NOT START AND I HAD TO GET A JUMP FROM AAA. THE CAR WAS NEW WITH LESS THAN 3000 MILES ON IT. I TOOK IT TO THE DEALER TO FOR A DIAGNOSTIC AND THEY KEPT IT FOR 5 DAYS. THEY HAD TO REPLACE THE BCM. THE BCM WAS LISTED AS PROBLEM IN PRIOR YEAR VERSIONS OF THIS VEHICLE. THIS APPEARS TO BE A CONTINUING PROBLEM WITH THIS VEHICLE. THE VEHICLE WAS PARKED AND WAS NOT BEING DISTURBED WHEN THE ALARM WENT OFF.