2021 Hyundai Kona Electric

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

On February 3, 2026, while driving in a high-traffic turning lane, my Hyundai Kona Electric vehicle suddenly lost propulsion and would not accelerate. The vehicle shut down without warning and could not be restarted. Traffic was building behind me, creating a safety hazard. I felt unsafe due to surrounding vehicles expecting movement, I contacted the police for assistance. The vehicle had to be towed from the roadway. The vehicle was transferred between 3 dealerships before being diagonsed. On February 16, 2026, the issue was diagnosed as a motor position sensor failure affecting the propulsion system. The vehicle has remained inoperable since February 3, 2026, and there is no repair ETA due to parts availability. The vehicle remains at the servicing dealership and is available for inspection upon request. There were no prior warning lamps, dashboard messages, or noticeable symptoms before the sudden loss of propulsion. This incident involved a sudden failure of the vehicle’s propulsion system while operating in active traffic and presented a significant safety concern.

NHTSA ID

11719765

Incident

Feb 3, 2026

Potential Fire and safety risk ... The Hyundai Kona Electric Vehicle (EV) has experienced issues with its Integrated Charging Control Unit (ICCU) due to problems with the low-conductivity coolant (BSC-1) used in models produced between 2018 and October 2021. This coolant can crystallize, forming debris that clogs the cooling system, leading to false "Refill Inverter Coolant" warnings and potential overheating risks. A Technical Service Bulletin (TSB 23-01-049H) outlines a recall to flush and replace the coolant with an improved BSC-2 formula to address this issue. However, improper or repeated coolant flushes, if not performed correctly using Hyundai’s specialized equipment and procedures, can leave air bubbles or residual debris in the system, which may impair cooling efficiency and stress critical components like the ICCU, inverter, and electric motor. Repeated coolant flushes, especially when not executed properly, can exacerbate issues by introducing air locks or failing to fully remove crystallized debris, potentially causing damage to the ICCU, inverter, and motor. Air bubbles trapped in the cooling system can reduce heat dissipation, leading to overheating that may degrade the ICCU’s electronics or cause the inverter and motor to operate at unsafe temperatures, risking premature failure. Posts on forums indicate that some vehicles required multiple flushes to clear the warning, with improper flushing sometimes leaving contaminants that continue to trigger sensors or obstruct coolant flow. This underscores the importance of having the procedure done by trained technicians using the correct tools to avoid long-term damage to these sensitive components.

NHTSA ID

11683955

Incident

Aug 12, 2024

File with NHTSA now please!!!! What do you have to lose??? If anything If they do an investigation we are safe post warranty. Report a Vehicle Safety Problem, Equipment Issue | NHTSA [XXX] The Hyundai Kona Electric Vehicle (EV) has experienced issues with its Integrated Charging Control Unit (ICCU) due to problems with the low-conductivity coolant (BSC-1) used in models produced between 2018 and October 2021. This coolant can crystallize, forming debris that clogs the cooling system, leading to false "Refill Inverter Coolant" warnings and potential overheating risks. A Technical Service Bulletin (TSB 23-01-049H) outlines a recall to flush and replace the coolant with an improved BSC-2 formula to address this issue. However, improper or repeated coolant flushes, if not performed correctly using Hyundai’s specialized equipment and procedures, can leave air bubbles or residual debris in the system, which may impair cooling efficiency and stress critical components like the ICCU, inverter, and electric motor. Repeated coolant flushes, especially when not executed properly, can exacerbate issues by introducing air locks or failing to fully remove crystallized debris, potentially causing damage to the ICCU, inverter, and motor. Air bubbles trapped in the cooling system can reduce heat dissipation, leading to overheating that may degrade the ICCU’s electronics or cause the inverter and motor to operate at unsafe temperatures, risking premature failure. Posts on forums indicate that some vehicles required multiple flushes to clear the warning, with improper flushing sometimes leaving contaminants that continue to trigger sensors or obstruct coolant flow. This underscores the importance of having the procedure done by trained technicians using the correct tools to avoid long-term damage to these sensitive components. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11683954

Incident

Nov 6, 2024

Manufacturing defect ... Took it in 4 times for "refill inverter coolant" warning . They had a campaign ' tried by couldn't get the light to go away . It was their first time ever performing this on an EV at Kerry hyundai alexandria . Now TD EV in mason Ohio is confirming my inverter failed as a direct result of the poor flushes and poor manufacturing. I am seeking for hyundai to cover all related costs. I haven't had my vehicle for over a month . It's out of warranty 'however this was a known issue they issued a campaign for 'and then couldn't fix the issue after 4 or 5 tries and 2 different hyundia dealers . All work performed will be listed at Kerry hounding in alexandria KY and Jefferson wyler hyundai cincinnati Ohio.

NHTSA ID

11677951

Incident

Jun 27, 2025

Hyundia has had my car in for the SAME recall 4 to 5 times . 6 total weeks this time around. The ""refill inverter coolant" light kept coming back on . The last time I got it home it had more issues than when I took it in and wouldn't even catch a charge . (EV) They fried my compassitor trying to fix the inverter coolant recall . I then took had to pay 450 for a diagnostic ' (Kerry hyundai alexandria) They said electric motor is bad and will cost 8000 to 9000. Got a 2nd diagnostic (Jeff wyler hyundai cincinnati) Completely different result- Zero mention of motor ' said Ac compasitor failed. (Had no issues prior to them working on the original recall ) The light for the recall is still on by the way and they want me to pay 3500 for new AC capacitor . (600 diagnostic included in that price ) " The dealership’s failure to properly perform the inverter coolant refill recall directly caused the AC compressor failure in my 2021 Hyundai Kona EV. Before taking the vehicle in for the recall, the AC system was fully functional, delivering cold air without any issues, and the car experienced no charging problems, indicating the battery and cooling systems were operating normally. The recall, intended to flush the inverter cooling system and replace the crystallizing BSC-1 coolant with BSC-2, was not completed correctly, as evidenced by the dealership’s admission that they couldn’t fix it. This botched service likely left air or debris in the cooling system, which, in Kona EVs with a heat pump, could overwork the AC compressor used for battery cooling during charging. The compressor’s failure shortly after the recall service, despite no prior issues, strongly suggests that the improper coolant flush caused undue stress on the compressor, leading to its $3,000 failure, which should be covered under warranty or as a goodwill repair due to the dealership’s error". [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11674690

Incident

Jul 4, 2025

The car was unable to charge using level 3 DC fast chargers, necessitating the use of a level 2 charger for an extended length of time in order to be able to return home. A Hyundai dealer replaced the charging inlet lock actuator (invoice attached).

NHTSA ID

11669567

Incident

May 31, 2025

After powering on the car, the dashboard displayed multiple brake system warnings, including the brake system warning light and a message on the LCD display that read "Check regenerative brakes." A Hyundai dealer replaced the integrated electric brake unit assembly (invoice attached).

NHTSA ID

11669350

Incident

Aug 16, 2024

My wife's car t-boned another vehicle, but the air bags didn't deploy. Luckily, she wasn't hurt badly, but the vehicle was deemed a total loss, so you can imagine the force of the collision. The forward collision warning and automatic emergency braking didn't activate either. I reported it to Hyundai. They sent an inspector to examine the vehicle, and I also showed them photos and a copy of the police report, but they claim that my car was hit on the side, and the pre collision system doesn't detect imminent side impact. That's completely outrageous. I don't know what their inspector wrote in their report, but the photos and police report are irrefutable proof that my wife had a frontal collision with the side of another vehicle. Hyundai kept denying it because they didn't want to help financially. I attached a copy of their determination letters (the second one was after I submitted a copy of the police report to prove that my wife's car is the one that hit the other vehicle, but Hyundai refused to see it as it happened). This is a link to see the interior and exterior photos of the vehicle: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11665430

Incident

Sep 1, 2024

Certain 2021-2023 model year Kona, 2021-2023 model year Kona Electric, and 2022-2023 model year Kona N vehicles may experience an inoperable horn that may be caused by foreign substances causing internal parts to oxidize. At Hyundai, we are committed to providing vehicles of outstanding quality and value. In an effort to meet this commitment, the warranty coverage for the horn assembly replacement has been extended to 10 years / 120,000 miles from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners.

Some vehicles may have an inoperable horn that may be caused by foreign substances causing internal parts to oxidize. Hyundai is extending the warranty coverage for the horn replacement under this condition to 10 years or 120,000 miles from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. If a horn needs to be replaced, follow the instructions within this TSB to install the latest design. Please note that any vehicles under 10 years/120,000 miles are covered by this TSB, even if vehicle is within original warranty of 5 years/60,000 miles.

Some vehicles may have an inoperable horn that may be caused by foreign substances causing internal parts to oxidize. Hyundai is extending the warranty coverage for the horn replacement under this condition to 10 years or 120,000 miles from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. If a horn needs to be replaced, follow the instructions within this TSB to install the latest design. Please note that any vehicles under 10 years/120,000 miles are covered by this TSB, even if vehicle is within original warranty of 5 years/60,000 miles.

The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN), that have been identified in U.S. vehicles following prior crashes, theft, or non‑certified airbag replacements. These inflators are not approved for use, may rupture during deployment, and have caused serious injuries and fatalities. Please see attached announcement, provided by NHTSA, for more details.

The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These inflators were not supplied, approved, or authorized by the vehicle manufacturers and have primarily been found in vehicles that previously experienced a crash and underwent airbag replacement using non-genuine parts. These dangerous inflators have ruptured during deployment, posing a serious risk of injury or death due to metal fragments entering the vehicle cabin. To date, Hyundai is aware of three people who have died while driving a Hyundai vehicle with one of these substandard replacement airbag inflators that deployed in what likely would have been a survivable crash. NHTSA has issued a public advisory urging vehicle owners and service professionals to have vehicles inspected if there is reason to believe that a non-genuine replacement airbag may have been installed. Vehicles with salvage or rebuilt titles, prior airbag deployments, or unknown repair histories may present a higher risk. NHTSA strongly cautions against self-inspection by vehicle owners and recommends inspection by trained technicians.

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation.