2025 Hyundai Santa Fe Hybrid Problems

The primary component failure is within the hybrid powertrain control architecture, specifically involving the transmission control system or internal transmission clutches/modules (TCM/HEV control module). The vehicle utilizes a 6-speed automatic transmission integrated with an electric motor. During highway cruising, the transmission locks into a single gear ratio or a protective "limp mode," resulting in a total loss of normal acceleration despite high engine RPMs. The vehicle and its components are fully intact and available for inspection upon request. My safety and the safety of others were put at severe risk because the sudden, unexpected loss of acceleration occurred while traveling at highway speeds in active traffic. When the transmission locked and power cut out, the vehicle rapidly shed speed and dropped to a hazardous 20-35 mph on a high-speed roadway. This created an immediate, extreme risk of a high-speed rear-end collision from vehicles traveling behind me, forcing me to make defensive lane changes toward the shoulder without normal engine power to navigate safely. This happens without warning no notices or errors pop up when it happens. The issue is intermittent and has been presented to an authorized Hyundai dealership technician multiple times. Because the vehicle often resets its communication modules and temporary limp-mode parameters once the ignition cycle is turned completely off and back on, the dealership technicians have encountered difficulty pulling permanent historical diagnostic trouble codes (DTCs). However, the failure patterns match a widely documented, repeating issue among 2025 Santa Fe Hybrid owners regarding HEV torque calculation or loose engine wiring harness pin tension

First Incident – XXX Weekend ([XXX]) Accelerating at an on-ramp to a major highway (I-37S) in [XXX], vehicle suddenly lost power. Speed dropped from 60 mph to 45 mph, then 28 mph, in a 65 mph zone during rush hour traffic. No apparent cause: had ¾ tank of fuel, a clean maintenance history, and no prior issues. Managed to reach the shoulder and, after several minutes, able to exit the highway. Vehicle would not accelerate above 35–45 mph and stayed around 30mph, and the hybrid battery showed less than 25% charge. Notified Red McCombs Hyundai (original seller). When a loaner vehicle became available, we brought the Santa Fe in. After a week, the dealership stated they could not duplicate the problem and returned the vehicle to us. Second Incident – XXX ([XXX]) On a planned trip from [XXX] to [XXX], again experienced a sudden and severe loss of power. While merging onto I‑10W, in [XXX], the vehicle speed dropped from 80 mph to 60, then 50, then 38 mph. Able to avoid a collision because of an unusually wide median where I could safely stop. Used GPS to find a local Hyundai dealer - Casa Hyundai of [XXX] - and drove there, using surface roads only. Turned vehicle in for maintenance and continued trip using a loaner vehicle. Casa Hyundai reported, days later, that despite logged error messages indicating problem with hybrid system and advising user to immediately stop, they were unable to isolate problem. Third Incident – XXX (Unknown location in [XXX]) Entering I-10E after fuel stop (80mph zone) and accelerating hard on a slight incline, again experienced sudden loss of power, slowing to less than 40 mph. Drove on shoulder for two miles to next exit 284 and stopped w/motor running to recharge. No error codes or warnings displayed on dash. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The primary component failure is within the hybrid powertrain control architecture, specifically involving the transmission control system or internal transmission clutches/modules (TCM/HEV control module). The vehicle utilizes a 6-speed automatic transmission integrated with an electric motor. During highway cruising, the transmission locks into a single gear ratio or a protective "limp mode," resulting in a total loss of normal acceleration despite high engine RPMs. The vehicle and its components are fully intact and available for inspection upon request. My safety and the safety of others were put at severe risk because the sudden, unexpected loss of acceleration occurred while traveling at highway speeds in active traffic. When the transmission locked and power cut out, the vehicle rapidly shed speed and dropped to a hazardous 20-35 mph on a high-speed roadway. This created an immediate, extreme risk of a high-speed rear-end collision from vehicles traveling behind me, forcing me to make defensive lane changes toward the shoulder without normal engine power to navigate safely. This happens without warning no notices or errors pop up when it happens. The issue is intermittent and has been presented to an authorized Hyundai dealership technician multiple times. Because the vehicle often resets its communication modules and temporary limp-mode parameters once the ignition cycle is turned completely off and back on, the dealership technicians have encountered difficulty pulling permanent historical diagnostic trouble codes (DTCs). However, the failure patterns match a widely documented, repeating issue among 2025 Santa Fe Hybrid owners regarding HEV torque calculation or loose engine wiring harness pin tension

While driving on a highway at approximately 60 MPH, the vehicle abruptly suffered a catastrophic loss of power and entered "Limp Mode," creating a severe safety hazard on the roadway. The vehicle was safely maneuvered and pulled over to the side of the road. Upon shutting the vehicle down and attempting to restart it after a few minutes, the powertrain completely failed to engage, refusing to shift into either Drive or Reverse. The vehicle became entirely disabled and required a flatbed tow to the dealership. ​Dashboard Warning Messages: - ​"Transmission Control System" - ​"Check Hybrid System" ​Diagnostic Trouble Codes (DTCs): - ​P177700 (Transmission / Hybrid Powertrain Control Malfunction) - ​P178400 (Transmission Control System / Electric Oil Pump or Actuator Circuit Fault)

While driving on a highway at approximately 60 MPH, the vehicle abruptly suffered a catastrophic loss of power and entered "Limp Mode," creating a severe safety hazard on the roadway. The vehicle was safely maneuvered and pulled over to the side of the road. Upon shutting the vehicle down and attempting to restart it after a few minutes, the powertrain completely failed to engage, refusing to shift into either Drive or Reverse. The vehicle became entirely disabled and required a flatbed tow to the dealership. ​Dashboard Warning Messages: - ​"Transmission Control System" - ​"Check Hybrid System" ​Diagnostic Trouble Codes (DTCs): - ​P177700 (Transmission / Hybrid Powertrain Control Malfunction) - ​P178400 (Transmission Control System / Electric Oil Pump or Actuator Circuit Fault)

**What component or system failed, and is it available for inspection?** The vehicle's electrical/power system failed, causing a complete loss of power while driving. This is the fourth occurrence of this failure. The vehicle is currently at the Hyundai dealership and available for inspection. **How was your safety or the safety of others put at risk?** The power failure occurred while driving on a busy road. The driver struggled to safely maneuver the vehicle (executing a U-turn) to get out of traffic and reach a safe location. The vehicle had to be towed as a result. **Has the problem been reproduced or confirmed by a dealer or independent service center?** The vehicle has been brought to the Hyundai dealership for this same issue four times. As of the most recent update, the dealership has not been able to identify the root cause or confirm a fix. **Has the vehicle or component been inspected by the manufacturer, police, insurance representatives, or others?** The vehicle is currently with the Hyundai dealership (manufacturer-affiliated) for the fourth time for inspection related to this issue. No inspection by police or insurance has been reported. **Were there any warning lamps, messages, or other symptoms prior to the failure, and when did they first appear?** There were no warning lamps, messages, or other symptoms prior to the failure. Warning lamps/messages appeared only after the vehicle lost power.

**What component or system failed, and is it available for inspection?** The vehicle's electrical/power system failed, causing a complete loss of power while driving. This is the fourth occurrence of this failure. The vehicle is currently at the Hyundai dealership and available for inspection. **How was your safety or the safety of others put at risk?** The power failure occurred while driving on a busy road. The driver struggled to safely maneuver the vehicle (executing a U-turn) to get out of traffic and reach a safe location. The vehicle had to be towed as a result. **Has the problem been reproduced or confirmed by a dealer or independent service center?** The vehicle has been brought to the Hyundai dealership for this same issue four times. As of the most recent update, the dealership has not been able to identify the root cause or confirm a fix. **Has the vehicle or component been inspected by the manufacturer, police, insurance representatives, or others?** The vehicle is currently with the Hyundai dealership (manufacturer-affiliated) for the fourth time for inspection related to this issue. No inspection by police or insurance has been reported. **Were there any warning lamps, messages, or other symptoms prior to the failure, and when did they first appear?** There were no warning lamps, messages, or other symptoms prior to the failure. Warning lamps/messages appeared only after the vehicle lost power.

While driving, the vehicle suddenly lost motive power on the highway and would not accelerate beyond approximately 20 mph despite accelerator input. There were no warning lights or check-engine light. The condition created a safety hazard because the vehicle could not maintain normal traffic speed. Hyundai dealer has been unable to determine the cause on other vehicles with the same problem, and was trying to discourage me from reporting this. They also said that they'd keep the car for 3 days, and likely return it with no diagnosis, so do I really want to go through this? They seemed unconcerned that this is a very dangerous issue in a highway.

The primary component failure is within the hybrid powertrain control architecture, specifically involving the transmission control system or internal transmission clutches/modules (TCM/HEV control module). The vehicle utilizes a 6-speed automatic transmission integrated with an electric motor. During highway cruising, the transmission locks into a single gear ratio or a protective "limp mode," resulting in a total loss of normal acceleration despite high engine RPMs. The vehicle and its components are fully intact and available for inspection upon request. My safety and the safety of others were put at severe risk because the sudden, unexpected loss of acceleration occurred while traveling at highway speeds in active traffic. When the transmission locked and power cut out, the vehicle rapidly shed speed and dropped to a hazardous 20-35 mph on a high-speed roadway. This created an immediate, extreme risk of a high-speed rear-end collision from vehicles traveling behind me, forcing me to make defensive lane changes toward the shoulder without normal engine power to navigate safely. This happens without warning no notices or errors pop up when it happens. The issue is intermittent and has been presented to an authorized Hyundai dealership technician multiple times. Because the vehicle often resets its communication modules and temporary limp-mode parameters once the ignition cycle is turned completely off and back on, the dealership technicians have encountered difficulty pulling permanent historical diagnostic trouble codes (DTCs). However, the failure patterns match a widely documented, repeating issue among 2025 Santa Fe Hybrid owners regarding HEV torque calculation or loose engine wiring harness pin tension

While driving on a highway at approximately 60 MPH, the vehicle abruptly suffered a catastrophic loss of power and entered "Limp Mode," creating a severe safety hazard on the roadway. The vehicle was safely maneuvered and pulled over to the side of the road. Upon shutting the vehicle down and attempting to restart it after a few minutes, the powertrain completely failed to engage, refusing to shift into either Drive or Reverse. The vehicle became entirely disabled and required a flatbed tow to the dealership. ​Dashboard Warning Messages: - ​"Transmission Control System" - ​"Check Hybrid System" ​Diagnostic Trouble Codes (DTCs): - ​P177700 (Transmission / Hybrid Powertrain Control Malfunction) - ​P178400 (Transmission Control System / Electric Oil Pump or Actuator Circuit Fault)

On 08/22/26 at approximately 11:45 AM I was stopped at a traffic light and struck by a Ford Pickup truck whose approximate speed was 45 mph as described in the police officer who witness the accident totaling my Hyundai 2025 Santa Fe. No airbags were deployed. According to the police officer the frame was bent as well. Please see attached vehicles pictures

Any of the airbags failed to deploy during a significant crash. It is not available for inspection due to it being investigated by insurance. The driver and passengers' safety were affected in that more bodily damage could have occurred if they had hit the steering wheel or any other part of the car. I do not know if the problem has been reproduced or confirmed by a dealer, as i have tried to reach out to the dealer and they have not contacted me back. The vehicle is still being determined as if it can be repaired or it needs to be totaled. There were no indications of warning lamps, messages or other symptoms prior to failure.

Vehicle was in driveway for 3 days. When I got into vehicle to drive I saw the windshield had a large crack on driver’s side approximately 16” long. No vandalism or rock damage caused this problem. Has to be a stress fracture.

Washer nozzles are non adjustable, and spray too low on windshield to effectively clean glass, especially at highway speeds. Severe visibility issue. I have reported the problem to Hyundai corporate customer service, who are escalating the issue to upper management. I have also brought the vehicle to my local dealer where it was purchased and made them aware of the issue. Dealer agreed with me, and has heard same complaint from many other owners of this model. This should be a simple fix by swapping in an adjustable nozzle.

My vehicle randomly slows it self down while driving. I would be pressing the gas and the car would voluntarily slow down on its own with no warning. This problem can lead to plenty of accidents due to me or any other driver around me being unaware when my vehicle will brake on its own. The problem has been confirmed by Hyundai Patterson of Tyler, Texas and they have worked on my car twice to fix the issue and it still hasn't been fixed. The issue started about a month ago and when the incidents would occur in the beginning their would be no warning lights on my vehicle’s dash. As of recently there maybe a check engine light that will pop up when the incident occurs. It's a hit or miss.

[XXX] - On re-entering the highway, after getting gas. accelerating slowly on ramp (passing 35-40 mph) - I crossed a patch of snow, the brakes locked up briefly! (Fraction of a second) I was about 2/3 up the ramp. No other vehicles near. 1000 miles on 2025 Sante Fe. Arriving home and searching on line I find others have experienced similar brake events on a range of Hyundai products. 29 degrees light snow, some slush, mostly clear road. Cruise control had been on prior to stop. I didn’t notice status during ‘event’ but noticed it was on when I was back on the highway. Lane keep and centering indicators on. Adaptive cruise was not on. No other events in the 20 miles home. No prior similar incidents INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact stated that while driving, a slow leak on the inside side wall right rear passenger side. The vehicle was taken when taken to the dealer to replace. Left front driver side, had a bubble in the side wall. The tire was replaced. In another occurrence, was noticed on the The vehicle was taken to the dealer where it was diagnosed with front right and back right bubbles on the outside wall of the tire. The manufacturer was not notified. The approximate failure mileage was 7,000. The

I’m reporting a recurring safety issue with the Pirelli Scorpion All Season MS tires (255/45 R20) factory-installed on my 2025 Hyundai Santa Fe Hybrid Calligraphy. At just over 7,500 miles, I began experiencing significant vibration at highway speeds. The dealership diagnosed the issue as defective tires — two were replaced, but the issue returned within 24 hours. I stopped driving the vehicle due to safety concerns. This problem appears to be common: I’ve found numerous reports of Scorpion MS tires showing early failure, poor balance, bulging, and premature/uneven wear — all within low mileage. They stated that it was still an inherent issue with the tires and I would need new ones. Thus I requested to have a different set tires given the issues with these. These issues compromise the vehicle’s stability and may present a serious hazard in wet or winter conditions. I’m concerned these tires are not structurally reliable and should not be standard on family SUVs like the Santa Fe. Hyundai and Pirelli should investigate this tire line for potential safety defects or recall. I understand that it is the Scorpion MS, AS Plus 3 and the Verde with these similar issues. Unfortuneately for some reason your site won't let me post my photo, but I was able to file it under the same VIN under my report for the Santa Fe.

The dealer is unable to remedy the defect within a reasonable time. It’s been two months with no fix and my family’s safety is in jeopardy.

Check emergency, stopping function alert. Check hybrid system stop safely. Both alerts came on the dash the steering wheel vibrated 11 other alerts popped up in the car steered me to the side of the road. It would not start again and This has happened four times in the 7 months I’ve had the car Hyundai cannot figure out what the issue is. In fact they tell me there is no issue because it’s not happening to them while it’s been there for almost a month.

Purchased new 2025 Hybrid AWD Santa Fe with 47 miles on 8/3/25 at 6pm. By 6:30am on 8/4/25 I noticed an occasional knocking when coming to a stop, reversing, turning and at times driving forward. The knocking became more frequent and noticeable as the day went on with more driving and not once did a service message or warning light display. At 1pm on 8/4/25 with an added 100 miles, I drove it to Hyundai Service Department to have them diagnose the issue which they immediately heard. After 8 days, I was told it was a control arm issue which them lead to a complete suspension rebuild on the driver side. I could have lost total control of the vehicle due to the bad control arm. They claimed the passenger side was fine and I picked up my car on 8/12/25 4pm. By 6:30am on 8/13/25 the knocking was back and car is pulling to the right. Car is back in the service shop to further investigate the knocking. I believe Hyundai is trying to cover up this issue as the service report they initially gave me had no mention of the control arm or suspension rebuild. I refused to sign and asked for another service report stating what the issue was and how it was repaired.

WHAT FAILED: A panoramic moonroof shattered before delivery and was replaced by the dealer before sale. Despite the replacement, loose tempered-glass fragments remained inside the occupant cabin, including the front passenger compartment and the second-row floor where my two minor children ride. One glass fragment also tore the passenger-seat leather. SAFETY RISK: Loose tempered-glass fragments left in occupant areas create a foreseeable laceration hazard during normal vehicle use, particularly for small children riding in the second row. The presence of enough glass to tear the passenger-seat leather demonstrates that hazardous fragments remained in the vehicle after the moonroof replacement. CONFIRMED BY SERVICE CENTER: Yes. The selling dealer Hyundai of Kirkland was aware that the moonroof had shattered and was being replaced before delivery. The salesperson disclosed the moonroof damage and showed us the vehicle in the service area while repairs were being performed before sale. INSPECTED / REPAIRS: Loose glass fragments were discovered the day after delivery, prompting an immediate call to the dealer and a return visit for cleaning and inspection. Glass fragments continued to be found afterward, requiring additional follow-up visits, including a second unsuccessful repair request approximately one month later. The dealership was aware that loose glass had damaged the seat; on 09/08/2025, the salesperson directed me to repair the tear myself with clear nail polish rather than initiating a warranty repair. See file attached with evidence. No repair orders or service documentation were provided for these interior repairs. The dealer ultimately performed cleaning, third-party leather restoration, and replacement of the passenger-seat cover on 11/04/2025. Because loose glass continued to be discovered after the second repair attempt, I purchased a Prosidium protection plan for future glass-related damage. WARNING SYMPTOMS: None. This was a pre-delivery issue.

I’m reporting a recurring safety issue with the Pirelli Scorpion All Season MS tires (255/45 R20) factory-installed on my 2025 Hyundai Santa Fe Hybrid Calligraphy. At just over 7,500 miles, I began experiencing significant vibration at highway speeds. The dealership diagnosed the issue as defective tires — two were replaced, but the issue returned within 24 hours. I stopped driving the vehicle due to safety concerns. This problem appears to be common: I’ve found numerous reports of Scorpion MS tires showing early failure, poor balance, bulging, uneven and premature wear — all within low mileage. These issues compromise the vehicle’s stability and may present a serious hazard in wet or winter conditions. I’m concerned these tires are not structurally reliable and should not be standard on family SUVs like the Santa Fe. Hyundai and Pirelli should investigate this tire line for potential safety defects or recall. It also appears that the it's the MS, verde and AS Plus 3 from pirelli that have these issues. You can find additional complaints regarding these with a google search. They will be on reddit and facebook.