NHTSA Complaint #11705614 — 2023 MERCEDES-BENZ EQS 450 4MATIC

While the vehicle was stationary and connected to a DC Fast Charging station (Electrify America), a thermal event occurred at the charging interface. The charging connector overheated and thermally fused (welded) to the vehicle's high-voltage charging inlet. The connector could not be released by the vehicle or the station. A technician dispatched by the charging network was unable to remove the connector using standard release protocols. The technician confirmed the equipment had failed and was forced to use physical leverage to pry the fused connector off, resulting in the fracture of the vehicle's charging receptacle. I couldn't charge the vehicle anymore and so I took it to the Mercedes dealership. The certified manufacturer diagnosis confirmed the failure was caused by a "loose connection" and thermal defect in the external charging station cable, not the vehicle. The high-voltage receptacle was destroyed. This failure mode presents a critical safety risk of fire and entrapment, as the vehicle could not be disconnected or moved during the thermal event.