2018 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.

The contact owns a 2018 Hyundai Santa Fe Sport. The contact stated that while attempting to start the vehicle, several warning lights illuminated and the ABS message was displayed. The dealer was contacted and made aware of the failure. The vehicle was scheduled to be repaired. The contact referenced a recall with a similar failure; however, the VIN was not under recall. The contact stated that the vehicle was unsafe to drive. The manufacturer was contacted and made aware of the failure. The failure mileage was approximately 56,000.

NHTSA ID

11775079

Incident

Oct 2, 2026

Mileage

56,000 mi

Odometer Fraud. The contact purchased a 2018 Hyundai Santa Fe Sport. The contact stated that after purchasing the vehicle, the local service center discovered a mileage discrepancy. The vehicle was a private dealer sale. At the time of purchase, the mileage was 123,546. The service center discovered that the mileage was 231,991.

NHTSA ID

11774653

Incident

Oct 30, 2026

Mileage

231,991 mi

This vehicle has been suffering from substantial engine oil consumption, burning oil at an alarming and unsafe rate. I have repeatedly brought the vehicle to Washington Hyundai to address this under the engine class-action lawsuit terms, but the dealership continues to run repetitive tests without a resolution. This is a critical safety issue. Excessive oil consumption poses a severe risk of sudden, catastrophic engine seizure or stalling while operating at high speeds on the highway.

NHTSA ID

11774019

Incident

Mar 24, 2023

My 2018 Hyundai Santa Fe is burning oil and I run the risk of engine failure. I have to check my oil level daily. The mechanic who performed my last oil change said he is seeing this frequently with this age Hyundai Santa Fe. He said Hyundai should be willing to replace my engine but of course they won't. I fear that I am going to be on the freeway and have sudden engine failure creating a risk for me and drivers around me.

NHTSA ID

11770237

Incident

Oct 9, 2026

While driving over the pass the car suddenly lost power and was running very rough. Luckily there was an exit close by that we took and the engine died on the exit. We were able to get it started and get to a parking lot where it died and would not start again. While trying to start it in the parking lot the check engine light came on. So, after a $375 tow to the nearest town the mechanic discovered a damaged spark plug and the compression test showed 0 psi. The scope showed a hole in the piston. The car also leaks and burns oil. The mechanic recommended scrapping the vehicle since it would not be cost effective to repair it. The mechanic said ours is the 6th Santa Fe in their shop with a blown engine in the past month. It has not been inspected by anyone else.

NHTSA ID

11768889

Incident

Oct 2, 2026

The driver window as well as the driver rear window fuse blows out. It poses a threat when you need to get the windows down in an event of emergency.

NHTSA ID

11767684

Incident

Apr 1, 2026

My 2018 Hyundai Santa Fe Sport (2.4L Theta II GDI, VIN [XXX], approx. 110,000 miles) has suffered a chain of engine and emissions-system failures that create a loss-of-power safety hazard. At about 80,000 miles, Hyundai replaced the original engine under warranty for excessive oil consumption, a defect Hyundai has acknowledged across the Theta II engine family. After only about 20,000 miles on that replacement engine, the catalytic converter failed and set a P0420 code. The vehicle now bogs down, hesitates, and loses power under acceleration. This is dangerous when merging or accelerating into traffic, where a sudden loss of power raises the risk of a collision. A restricted or failing catalytic converter causes exhaust backpressure and abrupt power loss, and the underlying oil consumption also risks low-oil engine damage and stalling. A catalytic converter should last far longer. This premature failure is consistent with the well-documented Theta II pattern in which engine oil consumption contaminates and destroys the converter substrate. It indicates the replacement engine Hyundai installed is itself consuming oil and damaging downstream exhaust and emissions components. I reported this to the dealer and to Hyundai. Hyundai declined to cover the catalytic converter, treating it as unrelated, even though its own warranty engine replacement is the direct cause. I am filing so this safety-related failure is documented. No crash, fire, or injury has occurred. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11764451

Incident

Sep 1, 2025

Bought this as a used vehicle with around 77k miles. The SUV was running fine for a little while until I drove onto the highway. It eventually began to bog down and there was hesitation and jumping instead of acceleration. This continued my entire trip home with the check engine light on. The car was only driven for about 300-400 miles in the time I had it. When I brought it to have an oil change, they found metal shavings in the oil. From what I’ve been reading, this has been a common problem for this vehicle. It has been sitting in a Hyundai service center for at least a month now with no real responses from Hyundai themselves. They told me they would not fix the problem due to lack of maintenance from prior owners and that they were marking my title (doesn’t make sense since I bought this with a clean title). According to what Hyundai told me, this issue was brought up by a previous owner in January 2026 with no repairs. How can you change the status of my title while refusing to repair a problem caused by a manufacturers defect?

NHTSA ID

11759687

Incident

Aug 25, 2026

In certain areas, a vehicle’s underbody may exhibit corrosion due to road salt usage. As a preventative measure, cavity wax coating is applied to the internal surfaces of underbody components, and an undercoating spray is applied to exterior surfaces of specified underbody components. This service campaign describes the procedure to perform this preventative service on certain Santa Fe Sport (AN) vehicles.

Certain Santa Fe Sport (AN) vehicles may exhibit underbody corrosion due to road salt usage. As a preventative measure, this bulletin provides the procedure to apply a cavity wax coating to internal surfaces of underbody components, and an undercoating spray to exterior surfaces of specified underbody components.

Some Hyundai vehicles may be equipped with a parking distance warning (PDW) sensor(s) that may trigger various DTCs and display warning messages on the instrument cluster, resulting in the PDW sensor(s) failing to detect nearby objects or triggering multiple false alarms. This condition may be a result of external damage to the PDW sensor membrane or sensor cover from rock chips or road debris, a collision, or previous vehicle repairs or modifications.

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.

Certain vehicles may exhibit excessive paint peeling or bubbling of the primer/paint film on the exterior metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. This warranty extension only applies to factory-applied paint and does not cover collision-related paint repairs or vehicles with a salvaged title. Hyundai is extending the warranty coverage for certain white paint colors under these conditions from 3 years and 36,000 miles, to 10 years with unlimited miles from the date of original retail delivery or date of first use, and is valid for original and subsequent owners.