2020 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.

I went to the store, came home , parked and turned off the car. Went to go outside about 10 minutes ,maybe. Black smoke coming from right front. By the time i grabbed the keys and fire extinguisher there were flames coming from the engine compartment

NHTSA ID

11756416

Incident

Aug 7, 2026

We were notified there was a recall and to schedule an appointment to get the update. We did and it was updated. It hesitated when we drove it the next day and everyday after. WE took it in a second time and was told by our dealer that following the completion of service campaign 9c2 certain vehicles may exhibit a brief hesitation or rough shifting conditions and to let it warm up for 1-3 minutes. We were told that Hyundai is working on it. It has been over a month and it still does it. I now own a 2020 Hyundai Santa Fe vehicle with less than 38,000 miles that is a lemon in my opinion. I am paying for gas to let it run for the 3 minutes and cant sell it or trade it in without a major reduction in price. I feel Hyundai is not being responsible for the damage they have caused to my vehicle.

NHTSA ID

11753119

Incident

Jun 19, 2026

I was quoted $3,000 to replace defective mat sensor in seat so that the airbag light will go off and my vehicle can be inspected. My family can’t afford this fix and I’m stressed out and do not know what to do. My vehicle was not in an accident nor was anything done that would cause damage and result in this fault. I am aware that the 2019 Santa Fe has an extended warranty for this exact defective mat sensor. My 2020 has the identical setup and failed just past the standard mileage limit. Because this is a critical SRS safety system that prevents my airbags from working properly I request help form the NHTSA. I read online a lot of owners are in my same situation.

NHTSA ID

11751706

Incident

Jul 20, 2026

I am currently burning through 2.5 quarts of oil approximately every 800 miles.

NHTSA ID

11751503

Incident

Jul 14, 2026

The contact owns a 2020 Hyundai Santa Fe. The contact received notification of NHTSA Campaign Number: 21V00M000 (Visibility); however, the part to do the recall repair was not yet available. The local dealer was contacted and confirmed that the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11751040

Incident

Jul 17, 2026

I am reporting severe safety risks and inspection fraud on my AWD 2020 Hyundai Santa Fe (VIN: [XXX]) caused by Universal Hyundai in Orlando. Inspection Fraud: The dealer falsified safety metrics, marking my brakes as a failing 4mm to push a $659.90 repair (RO# XXX), then passed those exact brakes at 5mm eleven days later (RO# XXX). Tire Malpractice: Mechanics over-inflated my tires to a dangerous 39 PSI and botched the alignment. This caused structural tire belt separation and severe sidewall bulges. The rear tire has suffered rapid, catastrophic deflation, dropping flat to 14.5 PSI and down to an empty 5.5 PSI. Crash & Drivetrain Risk: Operating an All-Wheel Drive (AWD) vehicle with a rapidly collapsing tire and asymmetric alignment forces the wheels to spin at mismatched speeds, creating severe friction that is destroying the internal powertrain transfer case and causing an immediate highway blowout crash risk. The service manager admitted "human error" and issued a full refund but banned my vehicle to avoid an audit. Hyundai Corporate has been notified under Case #XXX but has delayed resolution. Active consumer fraud file logged with the State of Florida under Case XXX. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11749944

Incident

Jun 4, 2026

The contact's daughter owns a 2020 Hyundai Santa Fe. The contact received a notification for an unknown emissions recall. The vehicle was taken to a local dealer, where it remained for three weeks, and an ECU software update was completed. The vehicle was then driven to the contact's residence. Upon restarting the vehicle, the vehicle jerked and chugged while driving. The manufacturer was notified of the failure, and a complaint was filed. The failure mileage was approximately 84,000.

NHTSA ID

11749004

Incident

May 18, 2026

Mileage

84,000 mi

Unknown

NHTSA ID

11745371

Incident

Dec 1, 2025

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.

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.

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 2019 – 2020 model year Santa Fe, 2017 – 2018 model year Santa Fe Sport, 2015 – 2019 model year Sonata, and 2018 – 2021 model year Tucson vehicles may exhibit elevated engine-out emissions. Hyundai is conducting a service campaign to update the Engine Control Module (ECM) Software for vehicles equipped with the (2.4 GDI) Theta II engine to improve engine combustion and fuel trim adaptations.

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.