2021 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.

For approximately the past year, my 2021 Hyundai Santa Fe, currently with about 23,000 miles, has experienced intermittent engine and fuel-system problems. During start-up, the vehicle sometimes makes an abnormal rattling/cranking noise, followed by noticeable engine and vehicle vibration. Warning lights may appear, and on some occasions the engine does not start successfully on the first attempt. When it does start, it may initially run rough. The vehicle has also stalled intermittently and has had repeated incidents where pressing the accelerator produced little to no engine response or acceleration. This creates a serious safety concern because the vehicle may unexpectedly stall, lose power, or fail to accelerate when needed while driving. The vehicle has been at an authorized Hyundai dealership for more than one month. The dealership has been working with Hyundai Tech Line and has replaced or evaluated the low-pressure fuel pump, high-pressure fuel injector, high-pressure fuel pump, MPI/port fuel injector, and valve cover. The latest recommendation is to drain, clean, and refill the fuel tank. Despite these repair attempts, the root cause has not been clearly identified or permanently resolved. I am concerned that the repair process has become trial and error, with additional components being replaced while the underlying safety-related issue remains unresolved. I am also being asked to pay out-of-pocket for some of these unsuccessful repair attempts. The vehicle is currently at the Hyundai dealership and is available for inspection if needed.

NHTSA ID

11775020

Incident

Oct 1, 2025

My 2021 Hyundai Santa Fe SE (VIN: [XXX]), with approximately 93,000 miles, has repeatedly experienced a dangerous loss of acceleration while driving at highway speeds of approximately 60 mph. When I press the gas pedal, the vehicle fails to accelerate, making it difficult to merge, pass, or respond safely to traffic. The vehicle does not suddenly slow down, but it will not increase speed when needed. This creates a serious safety risk to me and other motorists. The problem occurs without a check-engine light or advance warning. I have noticed abnormal behavior involving the Idle Stop & Go “A” indicator, which changes between orange and white. Coconut Creek Hyundai, an authorized Hyundai dealership, has inspected the vehicle multiple times. The dealership initially replaced the battery, then diagnosed and replaced the high-pressure fuel pump. The pump was replaced a second time due to a reported issue with the replacement. Software updates or resets were also performed. Despite these repairs, the original acceleration problem continued. The dealership has now diagnosed all four fuel injectors as severely clogged or defective and recommends replacing them. The service advisor stated in writing that the high-pressure fuel pump failure caused the injectors to fail. However, the dealership has not explained why this damage was not identified during earlier repairs or provided assurance that replacing the injectors will resolve the acceleration problem. Hyundai Motor America has been contacted regarding the repairs. The vehicle and dealership service records are available for inspection upon request. Availability of previously removed parts must be confirmed with the dealership. I request that NHTSA investigate this recurring highway acceleration failure as a potential vehicle safety defect. Multiple repair attempts have failed to resolve a condition that could result in a serious accident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11774943

Incident

Oct 6, 2026

The contact owns a 2021 Hyundai Santa Fe. The contact stated that while in reverse(R), the rear-view camera displayed a distorted pixelated image on the screen. The dealer and the manufacturer were notified of the failure and stated that there were no recalls associated with the VIN. Upon investigation, the contact discovered NHTSA Campaign Number: 24V879000 (Back Over Prevention); however, the VIN was not included in the recall. The failure mileage was approximately 40,000.

NHTSA ID

11773705

Incident

Sep 1, 2026

Mileage

40,000 mi

On September 20, 2026, my 2021 Hyundai Santa Fe Calligraphy suffered sluggish acceleration while operating on a public roadway due to an internal dual-clutch transmission (DCT) failure. The Malfunction indicator light illuminated, and a diagnostic scan revealed stored history code P1C2D03, indicating a total breakdown of the high-pressure electric pump assembly. As of September 21, 2026 the vehicle is currently grounded at an authorized Hyundai dealership under an approved factory warranty repair Prior Authorization (PA) request. However the dealership has issued a written admission of "NO ETA" because the replacement transmission components are on an indefinite national backordered and are no longer being manufactured . Because the vehicle cannot be repaired in a reasonable timeframe due to a severe factory design defect , it remains unresolved.

NHTSA ID

11770668

Incident

Sep 20, 2026

The contact owned a 2021 Hyundai Santa Fe. The contact stated that while his wife was driving 50 MPH, the vehicle unexpectedly caught on fire. The contact's wife became aware that the radio was inoperable before the failure. Additionally, the contact’s wife’s eyes were irritated, and there was a hot, harsh odor which grew stronger very quickly. The odor was inside the vehicle. The contact stated that the smoke was black, and flames started shooting out from under the hood to consume the vehicle. The vehicle was a total loss. The fire was extinguished by the Murphysboro Fire Department. The Fire Department was unable to determine where the fire had started. There was a Police report filed. The vehicle was towed to an impound lot. The failure mileage was approximately 58,000.

NHTSA ID

11763201

Incident

Sep 8, 2026

Mileage

58,000 mi

The door to the gas tank is a push door which is temperamental. I can be at the pump and push the door to pop it open and it won't. I'm at the point where I have to pop my gas tank open before I even get to the gas station because to pull up to the pump and not be able to put gas in the tank is a waste of time. There is no lever to flip along side the driver seat because it is a push to open door.. it is available for inspection, however, it is temperamental. I will video it so I have proof as it works and it doesn't work. It has not been inspected by anyone only because if it is a defect in the motor for the door, I want Hyundai to recall it. I have gone on YouTube to see if there are remedies and yes, there are videos on how to open the door in case you cannot push it open. I cannot do this because I'm not ruining the back of my car as there is no compartment to open as shown in the YT video. I am not one to let my tank get down to less than 1/2 tank, especially not now. But why am I worrying about popping the door open when I'm not even at the gas station yet??

NHTSA ID

11760005

Incident

Jun 15, 2026

My rear back up camera intermitting stops working. I can shift into reverse sometimes and the camera does not come on at all, other times the screen blinks and other times the screen has green lines and glitchy lines. The camera will also come on while I'm DRIVING forward

NHTSA ID

11756508

Incident

Jul 30, 2026

When i select (R) reverse my camera does not come on. It started as just a flashing screen, but does not come on. It has come on momentarily while I am (D)driving. it has flashed a green screen before.

NHTSA ID

11751769

Incident

Jul 11, 2026

This bulletin provides information related to the navigation and head unit software changes introduced in the 2026 2nd Navigation Map and Software Update. The changes may vary depending on vehicle type, model, and navigation system. Refer to the 2026 2nd Navigation Map and Software Update Key Improvements and Additional Improvements tables in this TSB for a list of specific changes. The software can be downloaded via Navigation Updater (NAU) and updated by USB.

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.

Some vehicles may have an inoperable horn that may be caused by foreign substances causing internal parts to oxidize. Hyundai is extending the warranty coverage for the horn replacement under this condition to 10 years or 120,000 miles from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. If a horn needs to be replaced, follow the instructions within this TSB to install the latest design. Please note that any vehicles under 10 years / 120,000 miles are covered by this TSB, even if vehicle is within original warranty of 5 years / 60,000 miles.

Some vehicles may have an inoperable horn that may be caused by foreign substances causing internal parts to oxidize. Hyundai is extending the warranty coverage for the horn replacement under this condition to 10 years or 120,000 miles from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. If a horn needs to be replaced, follow the instructions within this Technical Service Bulletin (TSB)26-BE-001H-2 to install the latest design. Please note that any vehicles under 10 years/120,000 miles are covered by this TSB, even if vehicle is with original warranty of 5 years/60,000 miles.