2023 Hyundai Santa Fe

Subject: Formal Dispute: Warranty Breach and Failure to Repair – 2023 Hyundai Santa Fe Timeline & Facts:11/2/25 (~52,000 miles): I officially reported an intermittent loss of power and severe engine revving (up to 7,000 RPM). This created a severe safety hazard when merging and accelerating from an idle stop.3/28/26 (Under 60k miles): After months of diagnostic delays, Hyundai confirmed the Dual-Clutch Transmission (DCT) needed replacement under the 60,000-mile warranty. A Hyundai Case Manager tracked the issue.Service Delay: Hyundai delayed repairs due to a lack of loaner vehicles, which were grounded for recall updates. Commuting pushed my mileage to 60,218. The Case Manager assured me coverage was locked in because the defect was documented before 60,000 miles.4/8/26: Due to corporate protocol, they ordered a valve body installation instead of a new transmission.8/11/26: The valve body failed. Hyundai delaership resubmitted the transmission replacement request. Corporate denied 100% coverage because the odometer was now over 60,000 miles (60,218). They are offering only 80%, leaving me with a $1,000 plus out-of-pocket expense.Legal & Contractual Position:Hyundai is contractually and legally obligated to cover 100% of this replacement. Under federal and state consumer protection laws, any defect reported prior to warranty expiration must be fully repaired by the manufacturer, even if the final repair occurs after the mileage threshold. The current mileage is a direct result of Hyundai’s internal diagnostic and loaner delays.Demanded Resolution:I demand that Hyundai cover 100% of the transmission replacement costs immediately. I am hoping this escalation to the NHTSA will help in bringing this matter to a positive end result, otherwise I have no choice but to pursue formal legal remedies.

NHTSA ID

11756570

Incident

Nov 2, 2025

This complaint concerns a serious, unresolved powertrain/propulsion safety defect in my 2023 Hyundai Santa Fe. While traveling approximately 70 mph, the vehicle suddenly lost propulsion and would not accelerate normally while surrounded by highway traffic.MOST IMPORTANTLY, THERE WAS NO WARNING OR ADVANCE INDICATION. No warning lights, messages, or symptoms appeared before the loss of propulsion. I had no opportunity to anticipate the failure or prepare to safely exit traffic. This placed me and other motorists at immediate risk of a serious or potentially fatal collision.A Hyundai dealership inspected the vehicle and documented DTC P284001, Shift Fork D Position Fault. Despite this documented fault, the underlying safety issue remains unresolved. Hyundai has not identified a permanent correction or established that the vehicle is safe to operate.There has not been another incident because I will not risk another sudden loss of propulsion by driving the vehicle. The absence of another failure does NOT mean the problem is resolved. The vehicle remains available for inspection.I have repeatedly sought assistance from Hyundai and the dealership without a meaningful resolution. Newer information regarding a possible computer reset/relearn procedure has also been presented, but the dealership refuses to perform it.I reviewed NHTSA complaints for 2023 Santa Fe vehicles and found multiple reports describing similar safety symptoms, including sudden loss of propulsion, inability to accelerate, abnormal transmission shifting, and loss of speed. This raises serious concern that this may not be an isolated failure.A vehicle that can unexpectedly lose propulsion at highway speed WITHOUT ANY WARNING creates an extreme crash risk. I respectfully request that NHTSA review the similar complaints, investigate whether a broader transmission/powertrain safety defect exists, and determine whether corrective action is necessary before this results in serious injury or death.

NHTSA ID

11755949

Incident

Mar 4, 2026

I was driving, and the SUV all of a sudden lost power. I was trying to press harder on the gas pedal to keep up with the traffic, but the SUV was stalling. The SUV would not move, and as I kept trying to press on the gas pedal, a roaring noise like something was trying to turn but the engine kept trying to move the car. It felt like something in the car was trying to move but something kept slipping. I had to turn the car off in the middle of the street and restart it before it would move. Cars were blowing their horns. This is a safety issue and a dangerous Problem. The SUV just did the same thing a few days ago. I am calling the dealer to see what is wrong. I brought this car new 2023. It is under 12,000 miles

NHTSA ID

11755136

Incident

Jul 7, 2026

The horn stopped working.

NHTSA ID

11754698

Incident

Aug 3, 2026

COMPONENT/SYSTEM: The powertrain launch control system — the Transmission Control Unit (TCU) and 8-speed wet dual-clutch transmission paired with the 2.5T engine — fails to deliver engine power in response to full accelerator input from a stop. The engine does not rev and the vehicle does not move for approximately 1–2 seconds despite the accelerator pedal being fully depressed, then power engages abruptly and violently. The vehicle is available for inspection upon request. SAFETY RISK: The failure occurs when launching from a stop into intersections and cross-traffic. In the most recent incident, I was turning left across the roadway from a stop with an oncoming vehicle approaching. I applied full accelerator and the vehicle did not respond at all for approximately 2 seconds — no engine response, no movement — leaving me stationary in the oncoming vehicle’s path. Power then engaged violently and without warning, causing the vehicle to lurch across the road. I was nearly struck. Similar events have occurred multiple times throughout my ownership; this was the closest to a collision. DEALER CONFIRMATION: Not yet inspected by a dealer. A dealer service appointment is being scheduled. OTHER INSPECTIONS: The vehicle has not been inspected by the manufacturer, police, or insurance representatives. WARNING LAMPS/PRIOR SYMPTOMS: No warning lamps or messages have appeared before, during, or after any of the events. The failure is intermittent and occurs without warning. The condition has been present since I purchased the vehicle in October 2022 and has occurred regularly throughout ownership — numerous occurrences over more than three years. No warning lamps have ever accompanied it. ADDITIONAL: Condition persists with Idle Stop & Go disabled, ruling out engine-restart delay. Same 8-speed wet DCT was subject to Recall 236 (NHTSA 22V-746) on 2021–2022 models for similar throttle non-response; 2023 excluded despite identical hardware.

NHTSA ID

11749868

Incident

Jul 11, 2026

My dealership has reground the rotors on my car twice. Now with less than 40,000 mileson the car the brakes need ground again. The issue with the brakes is it causes the front end of the car to shake when the brakes are applied. This could lead to loss of control on down hill stops in slippery conditions.

NHTSA ID

11748226

Incident

Jul 3, 2026

First Failure occurred 7 months after purchase at 5,270 miles on August 1, 2024. The vehicle suddenly went into "Limp Mode" abruptly decelerating to 25 mph with a non-responsive gas pedal. A code reader displayed PO653 Sensor Reference: "Voltage B Circuit High". Dealer found corroded wire to battery and cleaned it. Second Failure: Horn loss to 1 tone. Fixed at 30K mile dealer service on June 12, 2026 and found to have faulty packing resulting in corrosion. At the same standard service the Brake System was flushed. 3rd Failure was 5 days and 437 miles (30,712 miles) after the 30K dealer service. On June 17, 2026 during my early morning commute while merging onto the interstate, alarms began to blare and the gas pedal suddenly became unresponsive. The initial alarms read Blind Spot Failure. Car would not accelerate from 40 mph that it was going coming down the bridge ramp so I took the very close off ramp down from the aqua duct and the console display alert showed "Engine Management System: details: Braking and Body Control System with a recommendation to get "a full system check...TODAY". I brought it to the dealer that afternoon and as of yesterday, 6/26/26 they can find nothing wrong, declaring it an intermittent issue and asked me to come get the car, refusing to continue looking or providing alternate options other than referring me to Hyundai Consumer Affairs.

NHTSA ID

11746876

Incident

Jun 17, 2026

Vehicle stalled while driving — unsafe loss of power. While driving at normal speed, the vehicle suddenly shut off without warning and the electrical system malfunctioned. I had to pull over and restart car. This created a dangerous situation and could have caused a collision. Prior to this incidenct, the vehicle had intermittent electrical issues during startup (flickering electronics). This is the first time the car has experienced during driving, and is now at the Hyundai dealership. The car has been reported as unsafe to drive. This appears similar to other Hyundai stalling/power loss issues and may indicate a developing safety defect. Requesting investigation.

NHTSA ID

11746699

Incident

Jun 26, 2026

This bulletin provides information related to a Transmission Control Unit (TCU) software update for some vehicles equipped with an 8-speed wet dual clutch transmission (8WDCT). The software update revises the touch point learning variation, improving drivability and judder symptoms. Some 8WDCTs (indicated by a new part number) received an updated clutch spring. The correct TCU software update must be matched with the correct corresponding 8WDCT hardware, otherwise, drivability concerns may occur. This service procedure should be performed prior to any 8WDCT replacements done for drivability/judder concerns.

This bulletin provides information related to the navigation and head unit software changes introduced in the 2026 1st Navigation Map and Software Update. The changes may vary depending on vehicle type, model, and navigation system. Refer to the 2026 1st 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 vehicles may exhibit difficulty starting in cold weather. This bulletin provides the procedure to perform an inspection on the starter magnetic switch for potential freezing and, if necessary, replace the starter magnetic switch (solenoid) assembly.

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 2021 – 2023 model year Santa Fe, 2021 – 2023 model year Santa Fe Hybrid, and 2022 – 2023 model year Santa Fe Plug-In Hybrid vehicles may experience an inoperable horn that may be caused by foreign substances causing internal parts to oxidize. 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 horn assemblies under these conditions has been extended to 10 years/ 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.