2019 Hyundai Santa Fe

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.

Transmission was replaced under warranty by Hyundai in Nov 2024. Engine was replaced at 100600 miles in Nov 2025. Issues with the transmission were happening at that time but ignored by dealership as issues related to failing engine. Our mechanic confirmed in April that transmission was failing and told us to go to Hyundai. We went to dealer in April 2026. They confirmed transmission needed to be replaced. They were going to contact Hyundai USA. We received no updates despite many calls to the dealer. We had to call Hyundai USA directly. They opened a case. Dealer finally called and took car in and requested good faith repair by Hyundai USA. Hyundai USA responded 2 weeks later and is not covering anything. They replaced our transmission in Nov 2024 with a refurbished transmission that they NO LONGER MAKE. Clearly due to the fact that the refurbished part doesn’t work. They now want me to pay $8000 to repair transmission. My car has been maintained on schedule by my mechanic. All paperwork available. I have had Toyotas, Hondas and chevys that have lasted close to 20 years. This has been a horribly disappointing experience. And I now need to buy a new car for my 17 year old instead of handing down. I will NEVER buy another Hyundai. I want everyone to be aware of my experience. Disgusting customer service by Hyundai USA.

NHTSA ID

11752203

Incident

Apr 1, 2026

COMPLAINT SUMMARY: [XXX] / ENGINE THERMAL FIRE RISK / WARRANTY DECEPTION My 2019 Hyundai Santa Fe (2.4L GDI Engine) is experiencing severe powertrain degradation under the known Theta II engine defect class-action framework. On November 7, 2025, the vehicle logged a Permanent Diagnostic Trouble Code (DTC) P1326 via an independent scan, indicating catastrophic internal rod bearing wear. On XXX, the vehicle was brought to Hyundai of Milledgeville for safety recall verification. Instead of executing the mandatory corporate-directed Bearing Clearance Test (BCT) to replace the failing engine block, the service department committed technical campaign malpractice. The technician forced the 9C2 ECU Software Update directly over the locked mechanical fault to suppress the dashboard warning lights and alter the vehicle's ROM ID parameter limits. When caught via a photograph of their active GDS diagnostic tablet showing 7 historical system faults, the service manager provided a truncated printed report hiding Page 1 and omitting the critical P1326 powertrain code count to evade a warranty engine replacement. Due to these unmitigated delays, the vehicle has suffered severe consequential safety damage. The advanced engine degradation and oil consumption have flooded the exhaust system, melting the catalytic converter substrate and triggering a new DTC P042000 (Catalyst Efficiency) fault immediately after the dealer visit. The extreme engine vibrations have also damaged the transmission's torque converter clutch (DTC P074100). The dealership refused a service loaner and knowingly sent a disabled consumer and an elderly passenger away in an active, failing vehicle that presents a sudden stall-on-highway hazard and a severe thermal exhaust fire risk under extreme summer heat conditions. Hyundai Motor America Corporate has failed to provide emergency towing or alternative mobility accommodations despite a registered corporate case file. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(

NHTSA ID

11749805

Incident

Jul 8, 2026

On March 04, 2026, I took my 2019 Hyundai Santa Fe to the local dealer for oil change service. As part of that service visit, they performed Hyundai recall 9C1 which was supposed to lower tailpipe emissions. The next morning, and ever since, my vehicle ran differently. The engine had several 1000rpm surges and was sluggish at other times. This behavior has continued. Particularly when I first start out in the morning and the engine is cold. Never after the engine is warmed up. A visit to the Hyundai forum shows a growing list of other Hyundai owners who are experiencing the same issues. This recall is defective and should be corrected.

NHTSA ID

11742383

Incident

Mar 4, 2026

My 2019 Hyundai Santa Fe 2.4L (VIN: [XXX]) is experiencing a severe safety defect involving rapid engine oil starvation. The vehicle recently failed an official oil consumption test conducted by Fred Beans Hyundai of Abington, where it was documented that the engine consumed 1 quart of oil in just 881 miles (PA Request #XXX). This vehicle is equipped with the Theta II engine, which currently has active warranty extensions (TXXC and TXXI) specifically covering connecting rod bearing failure. Despite the documented severe oil loss—which is the primary known cause of connecting rod bearing wear and sudden engine seizure—Hyundai Corporate (Case #XXX) is refusing to evaluate the vehicle under these warranties. They have improperly classified my claim as a denied "goodwill" request and are refusing to perform a connecting rod bearing clearance test to determine if the bearings have been damaged by this starvation. Because Hyundai refuses to perform the required diagnostic safety protocols, the vehicle must be driven in an oil-starved condition. This poses an imminent and severe safety risk of sudden engine seizure, stalling, and complete loss of motive power at highway speeds without warning, which could result in a catastrophic crash. The manufacturer is ignoring their own failure thresholds and putting driver safety at risk. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11742308

Incident

Jun 4, 2026

In December 2025, a Hyundai dealer performed Service Campaign 9C2 (TSB 25-01-087H), an ECU software update for the 2.4L GDI Theta II engine, during a routine annual NY state emissions inspection. Immediately following this update, the vehicle began exhibiting an RPM flare of approximately 1,200-1,500 RPM during upshifting under light acceleration. This behavior did not exist prior to the update. The condition occurs when ambient temperature is above 50°F and the vehicle has been parked 2+ hours after a prior drive. No warning lamps or fault codes have been present at any point. The issue has been confirmed across four dealer visits at two Hyundai dealerships over five months. Attempted remedies included transmission ECU updates and adaptive resets — none resolved the condition. On the fourth visit, the technician personally experienced the issue and identified reinstalling the pre-update ECU calibration as the likely fix, but stated the prior software version was unavailable. The repair order was nonetheless closed as "vehicle operating as designed." The case has been escalated to Hyundai Motor America National Consumer Affairs and forwarded to Hyundai engineering with no resolution to date. Multiple other 2019-2020 Santa Fe owners report identical post-9C2 symptoms on public forums, indicating a pattern associated with this campaign's ECU calibration. The unexpected RPM surge and erratic shifting during acceleration creates an unpredictable driving experience that could cause hesitation in traffic situations requiring smooth acceleration.

NHTSA ID

11741031

Incident

Dec 1, 2025

Vehicle: 2019 Hyundai Santa Fe, VIN [XXX] , exterior Quartz White Pearl. Component: Exterior factory paint (paint/trim). Complaint: This vehicle exhibits a systemic, progressive factory paint defect — excessive peeling and bubbling of the white finish that spreads from one body panel to the next. This is a known defect across this vehicle generation; Hyundai acknowledged it by issuing Warranty Extension Z05 (TSB 25-BD-004H), which extends paint coverage to 10 years/unlimited miles for affected white-paint vehicles including the 2019 Santa Fe. Hyundai repaired the hood under this warranty in 2025, during which the vehicle was out of service for 77 consecutive days. Since that repair, the defect has migrated to the adjacent fender and has also appeared on a door, demonstrating that it is spreading across the vehicle. Hyundai has offered to repaint only the single currently-visible panel rather than addressing the systemic defect. I am filing this complaint to document the defect and its progression, and to support the public record regarding factory paint failure on these vehicles. No crash, injury, or fire has resulted. The vehicle is owned by my spouse; I am submitting as authorized representative. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11739369

Incident

May 7, 2025

Hyundai recently had a service campaign that was issued to address an emissions related issue in CA. The service campaign was 9C2 and the TSB was 25-01-087H. After this software update was applied to my vehicle the engine is now sluggish on a cold start and the transmission is shifting differently at low speeds and low gears. It appears that the performance of my vehicle has been compromised. There is a Hyundai forum where many Santa Fe owners are experiencing the same issues after the software update. I have notified the service advisor at my local Hyundai dealership.

NHTSA ID

11737086

Incident

May 1, 2026

Engine is burning a tremendous amount of motor oil. Dealer does acknowledge engine is burning oil. No warning lights on. Told burning motor oil is normal for a hyundai engine. Engine can seize during driving with no warning and is a safety issue. Front struts are also failing. No warning and is a safety issue: Currently trying to get dealer to cover defective components under warranty. Nothing has been repaired or resolved as of yet.

NHTSA ID

11736151

Incident

May 5, 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.

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. This bulletin provides instructions for updating the Engine Control Module (ECM) to address this condition.

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. The California Air Resources Board has determined that these vehicles may be releasing air pollutants which exceed Federal and California standards.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Certain Hyundai vehicles with exterior white paint may exhibit peeling or bubbling on metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. The paint warranty coverage for affected vehicles has been extended to 10 years/unlimited miles from the date of original retail delivery or date of first use and is valid for original and subsequent owners. The warranty extension does not apply to any vehicle that has ever been declared a total loss or sold for salvage by a financial institution or insurer or has a branded or similar title under any state’s law.