2017 Hyundai Santa Fe

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 Office of Defects Investigation (ODI) received a petition on February 2, 2024, requesting a defect investigation into an alleged defect of the "engine" on the following vehicle model: 2017 Hyundai Santa Fe vehicles equipped with the 3.3L V-Shaped GDI Lambda-II engines. The petition cites allegations of a loss of motive power, often resulting in an engine seizure. The stall is preceded by a knocking sound, decreased performance and no warning lights. An analysis of the subject vehicle population was undertaken using complaints submitted to ODI along with manufacturer data.  It was determined that the frequency of events is low for the subject population, while those that specifically report a loss of motive power event have a high mileage at the time of incident.  The 2017 Santa Fe is equipped with a service interval reminder for the consumer that must be set by the consumer themselves or at a dealership.  A Technical Service Bulletin (19-EM-002H) instructs the dealership to set the maintenance reminder at the completion of routine maintenance service or anytime a repair is performed that requires new engine oil.  This maintenance reminder will help reinforce the need for proper oil maintenance intervals.  Additionally, the Santa Fe vehicles with 3.3L V-shaped Lambda-II engines will be added to Hyundai’s existing Technical Service Bulletin (23-EM-007H) related to combustion chamber cleaning.  These actions will help limit negative consumer incidents related to loss of motive power.  Lastly, Hyundai has extended the limited engine warranty for MY 2013-2019 Santa Fe vehicles equipped with 3.3L V-shaped Lambda-II engines included in the Petition.  The updated coverage is 15 years, or 150,000 miles and details are contained in Technical Service Bulletin 24-EM-003H. In view of the service interval reminder, combustion chamber cleaning, and extended warranty actions being taken by Hyundai, ODI is denying this Defect Petition.  The agency reserves the right to take additional action if warranted by future circumstances.  To review the report cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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.

Complete unmitigated loss of acceleration and power while traveling at highway speeds, creating an immediate life-threatening road hazard. Following a warranty engine replacement and mandatory dealer software flash at Clay Cooley Hyundai (Sherman, TX), the vehicle began experiencing powertrain communication issues. While operating the vehicle at 65 MPH on the highway, the vehicle completely failed to accelerate and lost propulsion power, nearly resulting in a catastrophic rear-end collision with an oncoming 18-wheeler semi-truck. Dealership diagnostics claim "no trouble codes present," but live data telemetry confirms the High-Pressure Fuel Pump (HPFP) is actively commanding and delivering a dangerous 1,600 PSI to the fuel rail at hot idle. This abnormal fuel delivery is paired with a severe powertrain stutter in 3rd gear. Service personnel at multiple locations confirm a widespread, high volume of transmission failures and severe drivability issues specifically tied to this recent Hyundai software update. Corporate has denied repair coverage. The vehicle remains an active highway safety hazard and is completely undrivable.

NHTSA ID

11756411

Incident

Jul 8, 2026

The contact owns a 2017 Hyundai Santa Fe. The contact stated that while reversing, the vehicle jerked and shuddered abnormally. Additionally, the transmission hesitated, and the vehicle almost stalled. No warning lights were illuminated. The vehicle was taken back to the dealer where the contact was informed that the Service Campaign Number: 9C2 was completed. The contact was informed that the updated software was confusing the transmission and had caused the failure. The contact was informed that the remedy was not yet determined. In addition, the contact was informed that the dealer was waiting on instructions from the manufacturer. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 63,036.

NHTSA ID

11755907

Incident

May 22, 2026

Mileage

63,036 mi

Was driving down highway, 95 South in VA, when sunroof blew out. No traffic in front at the time, nothing hit the car. Driving around 65 mph. Temp outside was ~85-87, AC in car at 74. Just blew up and out after a large "Bang". There was no impact to the vehicle prior and no other marks or scratches to the vehicle indication an impact.

NHTSA ID

11755867

Incident

Aug 9, 2026

The 2017 Hyundai Santa Fe was brought to dealership on 3/27/26 for an oil change and a computer update was completed for Emissions Improvement. Upon picking the vehicle up after service, it was noticeable that it was not shifting correctly. I spoke to the service department and asked if the memory was cleared with the update an if it was having to relearn how I drive and the said it should not be affected. This went on for a few days and I left the car with them to duplicate as there were3 no stored codes. After a few weeks, the Teck Line recommended a new transmission, which Hyundai offered goodwill assistance. As we were waiting for the transmission to arrive from being on backorder, a bulletin for Service Campaign 9C2 was release on 5/18/26 that described my experience with shifting issue almost exactly. The transmission was replaced and the drivability issues still persist. Hyundai says that I must let my car warm up for 1-3 minutes to allow a catalyst to reach temperature and not cause rough shifting. This rough shifting is the effect of the update and thus te reason that my transmission needed to be replaced. Further investigation showed that this update is a known issue and cannot be reversed once installed. Currently, I must start my car in 90 degree weather to warm it up as a result of this update which is not logical in any thought process. I have asked Hyundai to cover the balance of the new transmission as this is a result of thier faulty software update with no success.

NHTSA ID

11755540

Incident

Mar 27, 2026

A Hyundai recall 9C2 update was applied to my vehicle. Ever since that update my vehicle hard shifts on cold starts which I fear is damaging the transmission. Hyundai dealer was able to replicate this and keeps advising us that concern is ‘under review with Hyundai’. I have the service order that states this. This problem has been ongoing for Months! I think Hyundai needs to find a resolution to this as my research indicates it is impacting a lot of customers.

NHTSA ID

11755044

Incident

Jun 24, 2026

The 9C2 campaign software update introduced dangerous vehicle hesitation and unpredictable gear changes in active traffic, presenting and immediate crash hazard

NHTSA ID

11753154

Incident

May 20, 2026

On June 10, 2024 at 107,129 miles Hertrich Hyundai dealership of New Castle inspected my vehicle and submitted a request to Hyundai for engine replacement under the recall settlement of the Theta II Engine Settlement. Hyundai denied the request because of the rebuilt title, even though the rebuilt title resulted only from prior Roof damage unrelated to the engine, powertrain, or recall issue. After continuing to seek assistance from Hyundai, my engine ultimately seized and suddenly stopped working on May 10, 2026, while driving on the highway with my two children. The vehicle lost power and stopped in traffic, creating a dangerous situation and causing my children extreme fear and distress. Had Hyundai honored the Theta II Engine Settlement when I first requested assistance, this failure could have been prevented. I request that Hyundai honor the Theta II Engine Settlement and replace my defective engine at no cost to avoid any future problems. My Hyundai Santa Fe is covered under the Theta II Engine Settlement. For over three years, I repeatedly contacted Hyundai after experiencing symptoms consistent with the known Theta II engine defect. Hyundai failed to provide meaningful assistance, did not properly process my requests, and denied coverage solely because of the vehicle’s rebuilt title.

NHTSA ID

11753050

Incident

Jun 25, 2026

I own a 2017 Hyundai Santa Fe Sport 2.4L (VIN: [XXX]). On XXX, my vehicle received Campaign 9C2 (ECU software update for Theta II emissions improvement). Shortly after this update, I began experiencing a drivability issue that did not exist beforehand. Description of the issue: The problem occurs only after the vehicle has been sitting long enough for the engine to become completely cold, typically overnight. During approximately the first 1/4 mile of driving, the vehicle intermittently jumps, surges, or lurches while accelerating normally. Once the engine warms up, the symptom completely disappears and the vehicle drives normally for the remainder of the trip. There are no warning lights, no check engine light, and no diagnostic messages. The Hyundai dealer has had the vehicle for nearly a week but has been unable to reproduce the concern. Because the issue only occurs during the initial cold start and first portion of the drive, I am concerned that it may not have been tested under the same conditions in which I consistently experience the problem. I am not claiming that Campaign 9C2 caused the issue, but the timing is notable because the symptom began only after the ECU update was performed. I am requesting Hyundai's assistance in determining whether: - the ECU update was installed correctly, - any required adaptation or relearn procedure is incomplete, - there are any related Technical Service Bulletins or software updates, or - additional diagnostics should be performed during a true cold-start drive with live data recording. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11751838

Incident

Jun 11, 2026

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 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.

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.

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.

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.

Certain Santa Fe / Santa Fe XL (NC) vehicles equipped with 3.3L Lambda II GDI engines may exhibit abnormal engine noise or damage. Technical Service Bulletin (TSB) 26-EM-002H describes the procedure to inspect the engine and perform the proper repair based on the results of the inspection. Utilize the flowcharts as a guide to ensure the proper procedure and repair is performed.