2015 Hyundai Santa Fe Sport

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

While I was driving my Theta engine got seized and Hyundai denied extended warranty of power train.

NHTSA ID

11750711

Incident

Jun 22, 2026

Today while driving to church we started hearing a ping noise ever so often. This just started then . After leaving church to go home the pinging noise got louder than the engine stalled and wouldn't start again. I had to have my car towed to my house. That is where it is now. The tow truck driver said that it was a rod. He said that he was mostly sure that it was happened. He stated that he has towed similar ones like mine with the same problem.

NHTSA ID

11749858

Incident

Jul 12, 2026

For a few months- the ABS light, Downhill assist light, and Slippery road light have all been on. Read it could be due to a bad sensor. Then on Saturday July 4th, I turned the car on and the Ebrake light was on but my ebrake was NOT initiated. Car was making a low humming noise on front passenger side of vehicle as well. I read the ebrake light could come on due to low brake fluid, so I wanted to drive it around the block to further try and diagnose the issue. My car then made a pop noise and started smoking from where the ABS pump is located and my tail lights all started flickering like Christmas lights. I instantly turned the car off and disconnected the battery to prevent an electrical fire. UPON researching- there is a recall for 2015 Santa Fe’s for this exact issue except mine isn’t on the list. I need to talk to someone who has seniority upon this situation because I have called Hyundai Customer service and my local dealership and nothing is being done or nobody cares to resolve this situation. My car is currently at a trusted local garage awaiting repair- I can not tow it back and forth between the garage and a dealership. I rely on my car for my children and work.. I can’t play around waiting for them to inspect it weeks from now. This is a serious issue as my children were also in the car. Everything is VERY similar to the recall on other 2015 Santa Fe’s..

NHTSA ID

11749067

Incident

Jul 4, 2026

FHW Garage used car dealer [XXX], sold this Hyundai Santa fe 2015 knowing the vehicle is defective. It Stalls and stops in the middle of the road in High Traffic. This Hyundai Santa Fe 2015 Lock up the Steering Wheel, Lock up the breaks, Lock up the gas. it Stalls and stops without Warning then after it freeze and stop it flashes all of the Warning Lights on the dash board. FHW Garage is Falsely Advertising this vehicle in Excellent Condition. Its Advertised on Craigs List, and [XXX]. I was almost in a Serious Accident. [XXX] keeps getting his people in the workshop to Machanically Rig the Vehicle to run and drive until someone gets killed when this vehicle is in a terrible Accident. The Gas Cap dont screw on properly. Fhw Garage [XXX] sold me this Vehicle with full knowlege of the Mechanical Defects, and refuses to give my money back. I paid $5,400 Cash plus traded my car. The Hyundai Santa fe was $6,900. Deceptive Practices Fraud, and Title Jumping. FHW still have the two cars after I purchased them. I would like to see FHW Dealer License Suspended or Revoked. Give my money back and return my car. I will be filing a complaint Affidavit with the FLHSMV. [XXX] lied on the Bill of Sales how much I paid and he put $900 in his pocket. I will also file a complaint to FHW [XXX]. For defrauding me, Misrepresentation saying the Vehicle is in Excellent Condition when its Mechanically Defective, and Dangerous should not be on the road to kill someone. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11747002

Incident

Jun 27, 2026

On 4/25/2026 I lost power on business freeway an orange light flash on along with whining noise I had to steer to right side shoulder for safety. Had it towed to dealership on 4/27/2026 they informed me 3 days later on 4/30/2026 that my car overheated. My car never overheated no smell of coolant nor no steam from the car when I exit to shoulder and turn car off. Retrieved manual from glove compartment it stated it had went into limp model. This has been a constantly nightmare my family could have been planning a funeral. These car manufacturers needs to be held accountable for their vehicle.

NHTSA ID

11746986

Incident

Apr 25, 2026

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving approximately 65-70 MPH, the check engine warning light started flashing, and the vehicle stalled. The contact was able to pull over to the side of the road, where the vehicle failed to restart and was towed to a parking lot, where a mobile mechanic diagnosed the vehicle and determined that the engine had seized. The vehicle was towed to the residence and then towed to the dealer, where it was diagnosed. The dealer informed the contact that the engine had failed, and there was sludge in the engine oil. The dealer informed the contact that the engine replacement could not be covered due to missing oil change documentation prior to the ownership of the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 155,000.

NHTSA ID

11730805

Incident

Mar 6, 2026

Mileage

155,000 mi

Engine failed while driving down the road, car was looked at by two mechanics with no known reason for engine failure so car was took to Hyundai of murfreesboro for diagnostic testing and was there for a total of 12 days for inspection, in which during that time i as asked to submit maintenance records for vehicle which i provided 18 pages of oil changes, other records. I was then told my claim was denied by Hyundai due to maintenance neglect as worded by the technician through a text message “is not proceeding with coverage on the engine due the cause of engine failure being maintenance neglect ” i received to other valid reason or cause, nor via email or in writing only a text message.

NHTSA ID

11729381

Incident

Mar 14, 2026

The contact’s daughter owns a 2015 Hyundai Santa Fe Sport. While the owner was driving approximately 70 MPH, the engine started making a knocking sound. There were no warning lights illuminated. The driver called the contact and was advised to pull over to the side of the road and turn off the vehicle. Once the vehicle was turned off, it was towed to a certified mechanic who was unable to diagnose the vehicle. The vehicle was then towed to another mechanic, who diagnosed the vehicle with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The vehicle was then towed to a dealer, who confirmed the failure and that the engine needed to be repaired. The dealer informed the contact of a Class Action Lawsuit for the engine failure and that the engine could be repaired; however, because the vehicle had not received the software update for Hyundai Campaign: (Hyundai TXXM Warranty Extension Number: 966/953/TXXM); the vehicle was no longer eligible to receive the engine replacement. The vehicle was not repaired. The manufacturer was made aware of the issue. The manufacturer opened a case. The failure mileage was 86,204.

NHTSA ID

11728772

Incident

Mar 13, 2026

Mileage

86,204 mi

Certain 2012 – 2017 model year Accent, 2012 – 2017 model year Azera, 2013 – 2018 model year Santa Fe Sport, 2013 – 2019 model year Santa Fe, and 2012 – 2017 model year Veloster vehicles may exhibit an intermittent airbag warning light and diagnostic trouble codes (DTCs) may be set. 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 Occupant Classification System (OCS)/Occupant Detection System (ODS) under these conditions has been extended to 18 years/unlimited mileage 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 listed below may exhibit an intermittent airbag warning light and DTC(s) B1763 (OCS ECU Defect), and/or B1764 (OCS Mat Defect) may be stored. Hyundai is extending the warranty coverage of the sensor for the Occupant Classification System (OCS) / Occupant Detection System (ODS) to 18 years/unlimited mileage from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. Refer to the warranty and parts information outlined in this bulletin.

Some vehicles listed below may exhibit an intermittent airbag warning light and DTC(s) B1763 (OCS ECU Defect), and/or B1764 (OCS Mat Defect) may be stored. Hyundai is extending the warranty coverage of the sensor for the Occupant Classification System (OCS) / Occupant Detection System (ODS) to 18 years/unlimited mileage from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. Refer to the warranty and parts information outlilned in this bulletin. This bulletin contains the procedure to inspect for the airbag warning light and DTC(s), replace the OCS (ODS) unit or wire harness, reset the OCS (ODS), and initialize the power seat module (if applicable). This TSB also contains the procedure to replace the OCS (ODS) mat if DTCs exist after replacement of the OCS (ODS) wire harness.

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.

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.

In response to this trend, we engineered a software upgrade that addresses the social media theft method and made it available to owners of eligible models free of charge at authorized Hyundai dealers since early 2023. In addition to the anti-theft software, we’ve developed a new zinc-reinforced ignition cylinder protector hardware upgrade that can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because your Hyundai vehicle with the VIN listed above (“Subject Vehicle”) was not factory-equipped with an engine immobilizer and was previously eligible for the software upgrade, you are now eligible until March 31, 2027 to have the ignition cylinder protector installed — if you request it — at no cost to you through an authorized Hyundai dealership.