2023 Hyundai Santa Fe Hybrid

The vehicle came to a complete stop filling cabin with smoke and wouldnt start in a bend on road blocking entrance ramp. Its available for inspection but at dealership. My safety was put at risk for collision as well as health with cabin filling with smoke. The dealer still has vehicle going on 3rd day without answers. The vehicle had warning come on for hybrid system failure appearing shortly before dying completely with smoke filling cabin.

NHTSA ID

11770334

Incident

Oct 8, 2026

I am submitting this formal safety complaint regarding a structural defect in my 2023 Hyundai Santa Fe Hybrid that I believe poses a safety concern and warrants federal investigation under the National Traffic and Motor Vehicle Safety Act (49 U.S.C. § 30101 et seq.). The vehicle exhibits a persistent and recurring structural creak originating from the pinch weld area adjacent to the hybrid battery storage compartment — specifically at a metal-on-metal contact point above the rear driver-side wheel well. The noise presents most prominently at low speeds over uneven surfaces, driveway transitions, and speed bumps. The root cause, as identified by service documentation and owner community reports, is a manufacturing defect in the pinch weld construction where two metal body components make contact due to insufficient clearance tolerances. This affects the structural integrity of the body-in-white in proximity to the hybrid high-voltage battery system. III. SAFETY SIGNIFICANCE I am reporting this as a safety concern for the following reasons: •The defect involves structural body components adjacent to the high-voltage hybrid battery storage compartment. Any degradation of body structure in this area presents a potential risk of battery exposure, puncture, or damage in collision scenarios; •The metal-on-metal contact at the pinch weld constitutes an ongoing structural stress point that may accelerate fatigue and cracking of load-bearing body components over time; •The defect is present across a statistically significant number of 2023 Santa Fe Hybrid units based on online owner community documentation, suggesting a manufacturing pattern rather than an isolated anomaly; •Multiple authorized Hyundai service centers have been unable to provide a permanent repair, indicating the defect is systemic and not addressable through routine service procedures; •The proximity of the defect to hybrid drivetrain components warrants evaluation for potential regulatory compliance

NHTSA ID

11741754

Incident

Mar 26, 2026

Own a 2023 Hyundai Santa Fe Hybrid and have experienced the following issues over the past year and a half. Beginning after maybe 40,000 miles we pulled out onto a roadway and the engine immediately lost power and started flashing a glaring red warning that the hybrid system was failing and to pull over. We luckily were able to and turned the car off and waited. I tried to turn it on and it came back to life as if there was never an issue? We drove off. it left no warning code or did not update my Bluelink App. I took it to the dealership and they could not find any issues. Fast forward another 5 or 6 months and it happens again. Take it to the dealer and they keep it a week to go over it but still nothing. Within a week of getting it back it happens again and this time I am videoing it happening to me. Back to the dealer and provide the video because again the car did not log the event nor did it update my app. They hold it again for a week and try different things. They still cannot figure it out and I get it back.... it happens again.... This time the dealership was able to come up with an answer and that the oil level was too high. I got the car back and it seemed to work. Probably now 6 months go by and then this week I drive over to Jacksonville (5 hr drive) and visit. Again the car scares us on the highway and I have to pull over. Havea friend meet us with tools and we jack up the car and let out enough engine oil to insure we can read between the two marks on the dipstick. We drive off but the engine keeps hestitating and we almost make it back before it completly shuts down. We tow it to the Dealer in Jacksonville. They call the next morning like they can't find anything wrong! I explain everything and remind I don't tow cars for fun - something is wrong with the car and it is leaving us vulnerable and worst is it is not leaving any codes. Not sure but I have lost faith in Hyundai

NHTSA ID

11719697

Incident

Feb 20, 2026

One two separate occasions while driving the car has lost the ability to accelerate. There is no acceleration power even when completely flooring the gas pedal. The dash displays a red circle warming that states "Check Hybrid system. Stop Safely". I have had to coast to the side of the road and then the car shuts off. It has taken several minutes before it can start again, and then displays a warning "Park with engine On to charge battery" before being able to shift the car into drive. I immediately took the vehicle to the dealership at which I had purchased the car. They have run a diagnostic on it and did not find any error codes stored in the computer. I picked up the vehicle from them and immediately upon pulling out of their lot it happened again. After losing power, coasting to the side of the road, and waiting for the engine to be able to restart I took it immediately back to the dealership. They have had my car for 5 weeks and cannot diagnose the problem or offer any recommendations for repairs.

NHTSA ID

11706383

Incident

Nov 11, 2025

The vehicle will not accelerate and comes to a complete stop while driving. Within days, it displayed ‘Check Hybrid System. Stop safely’ and lost propulsion while driving.

NHTSA ID

11704961

Incident

Dec 6, 2025

On September 4, 2025 as I pulled on to Interstate I-70 my car suddenly lost power. Gas engine died. Loud attention sound started. Instrument cluster started flashing red with message "EV system failure, stop immediately" EV battery showed full depletion although a moment before it showed about 75% power. There was only enough propulsion to keep moving slowly. Since this was a construction zone the shoulder was blocked off and roadway was reduced to only one lane. I had no where to go. A large truck narrowly avoided rear ending me. I was scared and felt helpless. Eventually I was able to pull off and shut off the car. It was able to be re-started immediately with no warning indicators and EV battery power restored. This loss of power has happened 6 times before during the time I have owned the car. Last time was in March 2025. Each previous time it happened I was traveling at about 35 miles per hour and while annoying I did not fear for my life. On March 6, 2025 I had the dealer, McCarthy Hyundai, check out this problem. There were no detectable problems or problem codes. I was told that it might have been caused by the oil dip stick not being fully seated. It was obvious they had no clue what caused this but that I should come back if it happened again. I have reported this to Hyundai customer service who would not confirm that this was a problem encountered by many others. From looking at reports on the internet, my problem is not unique except for being life thretening. Customer service had me bring it back to dealer. Yesterday, September 24, I picked up the vehicle whohad it for a week to try to fix the problem. Once again there were no error codes. Only problem they found was an ignition coil which needed to be replaced. They could not give a convincing explaination of how a bad ignition coil could cause a complete failure of the gas motor and EV system or why if the coil was sole problem that it would only cause this failure every 3 to 6 months. Please help!

NHTSA ID

11689613

Incident

Sep 4, 2025

I am reporting a serious and recurring safety defect with my 2023 Hyundai Santa Fe Hybrid, purchased new in January 2024. The vehicle has suffered from over 30–40 sudden hybrid system failures, including loss of acceleration, “Stop Vehicle” warnings, and check engine lights. These incidents happen without warning, including while driving at legal speeds (40–70 mph), on residential streets and highways. Most recently, the car failed twice in two days, while my teenage son was driving within all road laws, including once with a friend in the car. The vehicle simply stopped accelerating in the middle of traffic, endangering them and everyone around them. These failures have happened at legal speeds ranging from 40–70 mph, on both residential roads and highways. There is no advance warning, just abrupt loss of power and sudden warning messages. We’ve taken the vehicle to the South Charlotte Hyundai dealership multiple times. Each time, they either reset the check engine light or replaced indicators: but never addressed the root hybrid system failure. We filed a lemon law case, and Hyundai responded with only a $2,000 offer including legal fees, requiring us to keep the dangerous vehicle. We rejected the offer. These failures have occurred with children and passengers in the car. We have documented as many incidents as we could, including photos, service records, and communication with Hyundai. The vehicle is available for inspection upon request. I no longer feel safe driving or allowing my family to drive this car. This is a critical hybrid system failure that continues to place lives at risk. I believe this may be part of a wider pattern affecting Hyundai hybrid vehicles, and I am pleading with the NHTSA to open an investigation before someone is seriously injured or worse.

NHTSA ID

11675461

Incident

Jul 16, 2025

We were driving in Montana down [XXX] and heard a very large “pop” sound above us. Our vehicle was traveling alone in the area at the time, no other vehicles were around ours. There was no debris on the road or flying in air at the time, either. At this point the panoramic roof glass was closed but the interior cloth cover was open and there was no evidence of any damage. When we stopped for gas, the front glass panel covering behind the windshield and before the panoramic roof glass, was completely shattered. The weather was the same as it had been, 80F with minimal cloud coverage. There was no sudden change in weather/driving conditions.

NHTSA ID

11671450

Incident

Jul 6, 2025

This bulletin provides information related to the navigation and head unit software changes introduced in the 2026 2nd Navigation Map and Software Update. The changes may vary depending on vehicle type, model, and navigation system. Refer to the 2026 2nd Navigation Map and Software Update Key Improvements and Additional Improvements tables in this TSB for a list of specific changes. The software can be downloaded via Navigation Updater (NAU) and updated by USB.

Certain Santa Fe Hybrid (TM HEV), Santa Fe Plug-in Hybrid (TM PHEV), Tucson Hybrid (NX4 HEV), andTucson Plug-in Hybrid (NX4 PHEV) vehicles may experience intake air line freezing and Exhaust GasRecirculation (EGR) valve corrosion due to excessive condensation accumulating within the EGR system.This condition can lead to drivability concerns related to the following DTCs: - P040400: (Exhaust Gas Recirculation Control Circuit Range) - P049D00: (EGR 'A' Control Position Exceeded Learning Limit) - P047100: (Exhaust Pressure Sensor 'A' Circuit Range/Performance) - P012800: Coolant Thermostat (Coolant Temperature below Thermostat Regulation Temperature) - P262B00: (Control Module Power Off Timer Performance) - P050C00: Cold Start Engine Coolant Temperature Performance - P1DFD00: (EVAP System Purge Pump Target Speed) - P2DFD00: (EVAP System Purge Pump Performance) - P112000: (Inlet Metering Valve – Malfunction) - P033500: (Crankshaft Position Sensor A)

Certain Santa Fe Hybrid (TM HEV), Santa Fe Plug-in Hybrid (TM PHEV), Tucson Hybrid (NX4 HEV), and Tucson Plug-in Hybrid (NX4 PHEV) vehicles may experience intake air line freezing and Exhaust Gas Recirculation (EGR) valve corrosion due to excessive condensation accumulating within the EGR system. This condition can lead to drivability concerns related to the following DTCs: • P040400: (Exhaust Gas Recirculation Control Circuit Range) • P049D00: (EGR 'A' Control Position Exceeded Learning Limit) • P047100: (Exhaust Pressure Sensor 'A' Circuit Range/Performance) • P012800: Coolant Thermostat (Coolant Temperature below Thermostat Regulation Temperature) • P262B00: (Control Module Power Off Timer Performance) • P050C00: Cold Start Engine Coolant Temperature Performance • P1DFD00: (EVAP System Purge Pump Target Speed) • P2DFD00: (EVAP System Purge Pump Performance) • P112000: (Inlet Metering Valve – Malfunction) • P033500: (Crankshaft Position Sensor A) The bulletin below provides instructions to perform a software update for the Engine Control Module (ECM).

Certain Santa Fe Hybrid (TM HEV), Santa Fe Plug-in Hybrid (TM PHEV), Tucson Hybrid (NX4 HEV), and Tucson Plug-in Hybrid (NX4 PHEV) vehicles may experience intake air line freezing and Exhaust Gas Recirculation (EGR) valve corrosion due to excessive condensation accumulating within the EGR system. This condition can lead to drivability concerns related to the following DTCs: • P040400: (Exhaust Gas Recirculation Control Circuit Range) • P049D00: (EGR 'A' Control Position Exceeded Learning Limit) • P047100: (Exhaust Pressure Sensor 'A' Circuit Range/Performance) • P012800: Coolant Thermostat (Coolant Temperature below Thermostat Regulation Temperature) • P262B00: (Control Module Power Off Timer Performance) • P050C00: Cold Start Engine Coolant Temperature Performance • P1DFD00: (EVAP System Purge Pump Target Speed) • P2DFD00: (EVAP System Purge Pump Performance) • P112000: (Inlet Metering Valve – Malfunction) • P033500: (Crankshaft Position Sensor A)

Some vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin outlines the combustion chamber cleaning procedure for vehicles diagnosed with this condition. All internal combustion engines consume some engine oil during normal operation, depending on driving conditions and mileage, and this procedure should only be performed when deemed necessary based on inspection and diagnosis of the vehicle as outlined in TSB 26-EM-015H, Engine Oil Consumption – Inspection & Repair Guidelines, or the latest revision.

Certain vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin provides the inspection and repair procedures for vehicles exhibiting this condition. All internal combustion engines consume engine oil as part of normal engine operation. Oil consumption rates may vary based on mileage, operating conditions, driving habits, and maintenance history. Hyundai recommends following the prescribed maintenance schedule and periodically checking the engine oil level using the dipstick to maintain proper engine oil level.