[scardycat]

They did try replacing faulty cells and modules before the full recall, even though other manufacturers using the same LG cells were doing a full recall and replace. They also tried software fixes. I dont know enough to understand why it did not work.

[cptskippy]

They identified 2 defects and both defects were occurring in cells produced at multiple factories. That implies the defects were part of the process and not simply and issue with the setup of a single manufacturing line. It also implies that potentially all cells manufactured could have the defects.

[mastazi]

Probably the replacement program and the associated logistics were too expensive and the recall was an easier solution in terms of costs/benefits. Not sure about the PR costs this will cause though.