2018 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 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.

My 2018 Hyundai Santa Fe XL Limited was at a Hyundai dealership for a transmission replacement. While it waited for parts, it was parked outside on the dealership’s lot. It caught fire there while no one was working on it, and the cause is not yet known.

NHTSA ID

11773948

Incident

Oct 24, 2026

While driving, the vehicle developed a strong odor of engine oil, followed within minutes by illumination of the red oil pressure warning light. Inspection determined that a bolt had exited the engine's timing assembly, broken the timing chain, and punctured the timing cover, discharging engine oil throughout the engine compartment while the vehicle was in operation. Engine oil was sprayed onto hot engine and exhaust components while the vehicle was being driven on public roads. This presents a fire hazard. The same failure also risks sudden loss of engine oil pressure and seizure without warning, which would cause an abrupt loss of motive power in traffic. Approximately twelve days before this failure, the check engine light illuminated. The vehicle was taken for service within two days. The technician was unable to clear the code or identify the cause and advised a dealer inspection. No warning of imminent catastrophic engine failure was provided by the vehicle. The vehicle was towed to a Hyundai dealership, which quoted $6,932.28 plus tax and characterized the work as a "timing repair." This vehicle is equipped with the 3.3L Lambda II GDI V6. I am aware that this engine is the subject of Hyundai Warranty Extension TXX8 covering engine damage on 2013–2019 Santa Fe vehicles, and of a federal class action alleging premature failure of internal rotating components in this engine. The dealership's estimate made no reference to that extension, and Hyundai's public VIN lookup tool returns no campaigns for this vehicle. The vehicle remains at the dealership and the failed components are intact and available for inspection upon request. The failure was confirmed by both an independent service facility and the Hyundai dealership.

NHTSA ID

11766057

Incident

Sep 19, 2026

See attached letter for complaint

NHTSA ID

11744400

Incident

May 14, 2026

On April 13, 2026, I arrived home and parked the vehicle, engaging the traditional shifter into the "Park" position and turning off the engine. After exiting and standing on the ground to retrieve a purse from the cabin, the vehicle spontaneously and rapidly began reversing. ​As the vehicle gained momentum, I was struck by the driver-side door, which knocked me down and resulted in the vehicle running over me. The vehicle only stopped its rearward movement once it collided with a neighbor's parked car. Only after the vehicle began moving did the horn begin blaring, indicating a delayed rollaway alert. ​This incident resulted in a fractured ankle that required surgical intervention. Despite the traditional shifter being placed in "Park" and the engine being off, the vehicle failed to remain stationary, representing a catastrophic failure of the parking pawl or transmission engagement.

NHTSA ID

11735250

Incident

Apr 13, 2026

My wife was driving the vehicle by the left lane on route 9A northbound on elmsford at a speed around 35 mph. The vehicle suddenly came to stop completely while driving. My wife tried to start it but it didn't start. We called the police to come help us due to the ongoing traffic while the towing was on its way. Our mechanic told us the engine was seized and needs a replacement. The vehicle is a 2018 and has only 118000 miles. We do oil changes periodically every 3000 miles.

NHTSA ID

11730527

Incident

Apr 6, 2026

Catastrophic Engine Failure - Cam phasers blew apart and severely cracked the valve covers. This occurred with no prior warning lights. Minutes before failure, there was engine hesitation and noise and then severely reduced power, causing a safety issue while driving. Vehicle was towed to local Hyundai dealer who identified the cam phaser failure ausing external engine damage of the valve covers and complete loss of oil. This occurred only 3,000 miles after an oil change.

NHTSA ID

11724023

Incident

Dec 18, 2025

Engine Issues: A week ago, on two separate occasions, my Santa Fe cutoff while driving suddenly. A day later, I noticed a rhythmic knocking upon starting my vehicle. The knocking would increase during acceleration and decrease when I let off. I am only at 83,000 miles on this 2018 vehicle. I took the vehicle in for an oil change and they didn't notice anything off about the oil. Afterwards it slightly improved; however, once I was able to get it to the shop they said there were metal shavings in the engine/oil and it was a complete engine failure costing $12,000 to replace. There were no indicators that there was an issue on the dash.

NHTSA ID

11715002

Incident

Jan 21, 2026

Was driving and car turn off on me and wouldn't start I got it towed to Hyundai and they said my engine went out it had oil and everything we don't know why can stopped working has been sitting in my drive way for 3 years because we don't have 13000 that Hyundai told us

NHTSA ID

11701775

Incident

Feb 8, 2023

Certain 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. ****service campaigns 9A0/9A3/989/991/996

n 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 (NC) and Santa Fe XL (NC) vehicles.

Certain Santa Fe and Santa Fe XL (NC) 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.

Certain Palisade (LX2) and Santa Fe (NC) vehicles equipped with Lambda II 6-cylinder 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.