2023 Hyundai Santa Fe Hybrid Problems

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

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.

Between [XXX] am on [XXX]. I powered on my vehicle and the rear trunk door simultaneously opened. As I was driving my son to school that morning, I noticed water dripping onto my foot. I continued to drive but was distracted by beeping and warning messages but because the dashboard display was constantly switching from daytime to night lighting I could not readily see the dashboard. I tried to manually adjust the light by turning the knob off "auto" and also turning lights to "off" but it would immediately switch back. I made it to the first stop light and while stopped I was able to observe water droplets on the front panel of the interior fuse box. I pulled open the panel and water dropped out onto to floor. I replaced the panel. I continued to drive but was panicked and worried that water was in the fuse panel area. I arrived at my son's school and left the car running as he was dropped off. On the drive home, the beeping continued. This time, I saw the warning message about vehicle in my blind spot but I was on the street corner about to make a right turn and there was no vehicle next to me! The lights also kept switching as before. There was rust observed in the fuse panel area. When I got home, I called the dealership to inform them what happened. They refused to give me a loaner. I told them that water intrusion should not have occurred (we had severe weather and heavy rains the day prior) and now my car was having electrical issues and I was concerned for my safety and the safety of driving my 3 young children in car seats should there be an electrical fire. I mentioned the recall on my vehicle for water accumulation in the tow hitch and risk of electrical fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owned a 2023 Hyundai Santa Fe. The contact stated that his partner was driving at 50 MPH, a light ahead had just turned red, with two vehicles stopped just a couple of feet ahead of her, the contact stated that his partner had proceeded to frantically attempt to brake, however, the vehicle did not brake in time, and the automatic braking assist did not initiate. The complete front end of the vehicle was destroyed, as the vehicle crashed into the vehicle ahead. There was no property damage. The vehicle came to a stop after the crash. The driver's side air bags were deployed, however, the contact emphasized that it appeared the air bag had not fully deployed. The vehicle was towed to a lot. No warning lights had illuminated. A police report was filed. The vehicle was destroyed. The contact partner was injured, and she was seated in the driver's seat, and a single civilian seated in the driver's seat of the vehicle that was hit from behind was injured. The contact stated that his partner suffered injuries to her chest, and the other individual suffered injuries to the neck. Medical treatment was needed for both individuals. The local dealer was contacted however the vehicle was not diagnosed, as the vehicle was a total loss, and the manufacturer was not notified of the failure. The approximate failure mileage was 23,824.

I am reporting an URGENT REQUEST IMMEDIATE ACTION REGARDING A SERIOUS UNRESOLVED, RECURRING PUBLIC SAFETY ISSUE WITH MY VEHICLE. IT IS POTENTIALLY THE FAULT OF ALEXANDRIA HYUNDAI'S SERVICE DEPARTMENT (in Alexandria, VA) WHO HAD JUST SERVICED MY VEHICLE FOR WHAT SHOULD HAVE BEEN A ROUTINE SERVICING (on May 7). My car had a catastrophic and complete failure on a high speed highway (the car quickly decelerated) which represented an incredibly danger situation for myself and other drivers on the road. My car was purchased in 2023 and has 15,241 miles. It has been perfectly maintained. On [XXX], I was returning to my home in Virginia from Maryland on an 8 lane highway with a 55mph speed limit when I had a very dangerous complete failure of my car. Simultaneously, the car started bucking back, the speed was decelerating regardless of my pressing the accelerator to keep my speed the same as traffic, and I received a flashing large red message that said "CHECK HYBRID SYSTEM - STOP SAFELY." Fortunately I was in the far right lane and was able to veer it over to a narrow shoulder. It was 8pm and getting dark. After a short while, the car lost all power so I was on a narrow shoulder with no lights flashing anymore. I was in this dark car with a lot of traffic speeding my with my 2 dogs. I became incredibly stressed about how we were going to get home. I contacted AAA, a police officer and Uber Pet who worked together in this unsafe situation on the side of the highway to get myself and my dogs home into the Uber vehicle with only the front door opening (no power). It was over 2 hours before I was home safely It was incredibly stressful situation. The car was towed to Alexandria Hyundai and they dismissed the issue and fixed nothing. I contacted Hyundai customer service and asked for escalation and they have done nothing. I am restricted in my driving because of the severe safety risk but had to drive again on [XXX] and it occurred again on a highway INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U

Santa Fe will randomly experience inability to accelerate. I will hit the gas pedal, the engine will rev all the way up to power, it will slowly crawl forward and than violently accelerate. From the time I hit the gas pedal to the time it actually starts moving takes several seconds. It does this every time I come to a stop once it starts. It has done this 4 occasions now. It puts me at significant danger trying to turn across traffic. In general, it not accelerating as you would expect is a very dangerous situation. Dealer has had the car for over a month and has had the car reproduce the issue. The HEV light and check engine light had come on a couple of the occurrences.

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.

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.

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

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.

Driving down interstate at 70 mph and car started to brake while foot on gas pedal. Would not go…red brake alert came on. Luckily no other car in left lane and pulled off to side of road. Car would not drive. Called tow truck.

Occurred on [XXX] while travelling in the middle lane of a 3-lane highway just west of Raleigh, NC and heading west. The Emergency Brake Light came on, the car stopped suddenly and my head shook from side to side. This could have been a major accident if the traffic wasn’t light. I do not tailgate and there were at least 6-8 car lengths between me and the car in front. No cars on either side. There was no beeping warning from the vehicle about being too close to other vehicles before the car stopped. I pressed on the gas pedal and the car moved forward. The weather was about 50-60 degrees, dry road and sunny. Next Step: Called Hyundai Customer Care on [XXX] and was advised to bring the vehicle in for inspection and correction. Took the car into the Hyundai Autonation dealership in Buford, GA, where the vehicle was purchased. They found nothing wrong. Note: Have researched this problem online and found multiple instances of the same occurrence. See the following online: Emergency Braking System Activates Intermittently | Hyundai Santa Fe Forums INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

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

Incomplete weld(s) in frame/body at drivers side rear passenger seat floor area. Dealer has vehicle and is unable to repair frame/body weld(s) without removing body from frame. Frame/body flexing in the area of hybrid batteries are will continue to worsen over time causing possible short in wiring and or batteries causing fire. Dealer has confirmed issue. Manufacturer is buying back above vehicle at this time. Only warning sign was a persistent rattle in frame/body in driver’s rear passenger floor.

As my wife and I were traveling down the interstate at 45 mph, we heard a loud POP, but we were unable to figure out where it came from. Just a few seconds later, the sunroof exploded into a million tiny pieces of glass that partially rained down on our heads and shoulders. It was quite a startling sound. There was a hole about 8 inches across in the moveable sunroof and more pieces were continuing to fall out. To protect our heads, I closed the shade. There was no evidence of an object striking. Windows were all closed when the incident occurred.

We were driving at around 55mph and Panasonic sunroof exploded as is something hit it: however, nothing did. The glass tattered and fell on top of us (driver and passenger). We were unhurt but quite shook up.

Between [XXX] am on [XXX]. I powered on my vehicle and the rear trunk door simultaneously opened. As I was driving my son to school that morning, I noticed water dripping onto my foot. I continued to drive but was distracted by beeping and warning messages but because the dashboard display was constantly switching from daytime to night lighting I could not readily see the dashboard. I tried to manually adjust the light by turning the knob off "auto" and also turning lights to "off" but it would immediately switch back. I made it to the first stop light and while stopped I was able to observe water droplets on the front panel of the interior fuse box. I pulled open the panel and water dropped out onto to floor. I replaced the panel. I continued to drive but was panicked and worried that water was in the fuse panel area. I arrived at my son's school and left the car running as he was dropped off. On the drive home, the beeping continued. This time, I saw the warning message about vehicle in my blind spot but I was on the street corner about to make a right turn and there was no vehicle next to me! The lights also kept switching as before. There was rust observed in the fuse panel area. When I got home, I called the dealership to inform them what happened. They refused to give me a loaner. I told them that water intrusion should not have occurred (we had severe weather and heavy rains the day prior) and now my car was having electrical issues and I was concerned for my safety and the safety of driving my 3 young children in car seats should there be an electrical fire. I mentioned the recall on my vehicle for water accumulation in the tow hitch and risk of electrical fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

While driving the blind spot safety system, driver attention warning system, and lane following system malfunction at the same time, and the vehicle loses power steering. The first time this occured was in the parking lot of an elementary school in April 2024. I was driving less than 2mph and the vehicle had less than 8,000 miles on it. The dealer said they would be unable to diagnose unless they witnessed the errors. The second time it occured was in May 2024 while driving on the interstate at around 75mph. The vehicle was driven directly to the dealership who kept it for four weeks. They said the connections to the ECU were severely corroded, sanded them down, and added a water protectant. The third time it occured was a month later. The dealership has had the vehicle for two weeks with no diagnosis. Losing power steering suddenly while driving is incredibly dangerous, especially in a vehicle of this size and weight. It is difficult to control the vehicle without power steering, and in all cases there have been other vehicles/people in the area who could have been injured.

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

This tire was observed as defective in an inspection at Holler Hyundai in Winter Park FL. It was supposed to be mailed to Continental Tire for inspection, but the dealership failed to do that. I have photos of the defect (wire protruding for inside side wall). Every effort to discover the tire's location has been frustratingly stonewalled by the folks at the dealership. This tire's lot might be dangerous to other drivers and needs visible inspection.

The contact owns a 2023 Hyundai Santa Fe. The contact received notification of NHTSA Campaign Number: 23V181000 (Trailer Hitches) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not notified of the issue. The contact had not experienced a failure. Parts distribution disconnect.