2015 Hyundai Sonata Hybrid

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.

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

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.

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.

The Hybrid system kept crashing ! Triggering the auto theft and would not connect to fob , told it was immobilzer, and/or shortage in EV battery!!!

NHTSA ID

11754721

Incident

Jul 28, 2026

Component Involved: Hybrid Propulsion System High Voltage Battery / EV Battery Electrical System Power Train Incident Summary: I am reporting a serious and repeated safety defect involving my 2015 Hyundai Sonata Hybrid. This vehicle has experienced three separate incidents where warning messages related to the EV/hybrid battery system appeared, followed by a sudden loss of forward propulsion. During these events, the vehicle would not move properly or lost the ability to accelerate safely. This defect creates a major safety hazard because it can occur while driving, increasing the risk of being rear-ended, stranded in traffic, collision, injury, or property damage. I transport my small children in this vehicle and no longer feel it is safe. Detailed Timeline: Initial Incident: Vehicle displayed warning messages involving the EV/hybrid battery system and lost the ability to move forward properly. Vehicle had to be shut off and restarted. Independent Mechanic Inspection: Vehicle was inspected by an independent mechanic who advised the hybrid battery system likely needed repair or replacement and recommended service through Hyundai dealership. Dealer Visit #1 – Stew Hansen Hyundai (3/18/2026): Vehicle was taken to authorized Hyundai dealer for diagnosis. Dealer stated they could not duplicate the issue and no repair was made. Second Failure: After release from dealer, same dangerous loss-of-power condition occurred again, resulting in towing and additional inconvenience. Dealer Visit #2 – Stew Hansen Hyundai (4/8/2026): Vehicle returned to dealer for same issue. Dealer performed software update and stated this should correct problem. Dealer advised vehicle had been driven approximately 40 miles and was safe to release. Third Failure (4/12/2026 approx.): Only two days after picking vehicle up on 4/10/2026, same warning messages and propulsion failure occurred again. Safety Concern: This repeated loss of propulsion without warning is extremely dangerous.

NHTSA ID

11731825

Incident

Mar 18, 2026

Idle and warning to not drive, 2025 very subtle cut off now full warning

NHTSA ID

11730590

Incident

Apr 1, 2025

We pulled up at Hillgreen circle Cockysville MD To drop my boyfriend off at his apartment. I went to pull in the parking spot.I went to put the car into park and it had no brakes. I was slamming them and pumping them. It excellerated and took off. Jumped the curb,went down the hill and into the apartment building. A red light had came on the dash, right before it took off. Seemed like it was changing to gas or the electric mode,or the other way around. The airbag on the passenger side came out deflated,and filled with smoke going into the car. He was the belted front passenger and his elbow went in to the front window. You can tell by looking at it,the hole and spidered around it. He broke his right elbow. It is available anytime at the moment. It's at Hyundaii in Glen burnie. I need to get it to state farms lot,to get the Kelly blue book value. We look forward to hearing from you

NHTSA ID

11717654

Incident

Sep 14, 2025

The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated that while driving 5 MPH and making a left turn, the vehicle made an abnormal knocking sound. The contact stated that upon pulling into an apartment complex parking lot, the contact noticed that there was smoke coming out from underneath the hood. There was no warning light illuminated. The contact immediately parked and exited the vehicle. The contact stated that upon opening the hood, the contact noticed a small fire and was able to extinguish the fire with a water bottle. The contact was able to push the vehicle into a parking space with the assistance of her son. There was no injury sustained. No police report was filed. The vehicle was towed to an independent mechanic, where it was diagnosed that a fluid leak from an unknown hose had caused the fire, and there was a hole in the engine block. The contact also stated that there was a puddle of fluid on the ground. The vehicle was not repaired. The contact became aware that the VIN was included in NHTSA Campaign Number: 23V651000(Service Brakes, Hydraulic), which the contact related to the failure. The dealer and the manufacturer were not notified of the failure. The failure mileage was approximately 115,395.

NHTSA ID

11653864

Incident

Apr 7, 2025

Mileage

115,395 mi

The contact owns a 2015 Hyundai Sonata Hybrid. The contact took the vehicle to the dealer to be repaired under NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) and Manufacturer recalls: 964 (Auxiliary Canister Installation), 966 (Engine Monitoring Module, ECU Software Update), and 994 (Hybrid Safety Fuse). The contact stated that after the repairs were completed while attempting to start the vehicle at the dealer, the vehicle failed to start. The vehicle remained at the dealer who was unable to determine the cause of the failure. The vehicle had not been repaired. The manufacturer was made aware of the failure and confirmed that the vehicle was not covered under warranty for any further repairs. The failure mileage was 170,000.

NHTSA ID

11618944

Incident

Sep 28, 2024

Mileage

170,000 mi

The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while driving at various speeds, a message advising to pull over and to park the vehicle was displayed. The vehicle was taken to the dealer for diagnostic testing several times. The dealer replaced the HECU and the battery inverter assembly; however, the failure persisted. Additionally, the contact stated that while his son was driving at an undisclosed speed, the contact's son noticed that there was white smoke coming from the rear middle seat of the vehicle. An unknown warning light was illuminated. The contact's son pulled to the side of the road and turned off the vehicle. The vehicle failed to restart and was towed to the dealer, where it was diagnosed that the hybrid battery pack had failed, causing the hybrid battery to melt. The dealer determined that the hybrid battery pack needed to be replaced. The vehicle was not repaired. The contact related the failure to Hyundai Campaign Number: 994. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 37,000.

NHTSA ID

11605140

Incident

Dec 15, 2019

Mileage

37,000 mi

The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while driving 45 MPH, the vehicle started overheating, and smelled an abnormal electrical burning odor inside the cabin. Several unknown warning lights were illuminated. The contact veered to the side of the road, turned off the vehicle and inspected under the hood. The contact stated that the vehicle failed to restart and was towed to the residence. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) which he related to the failure. The dealer was notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.

NHTSA ID

11584561

Incident

Apr 22, 2023

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.

This TSB references the Op codes to use for claim submission and the Parts required based on the vehicle’s inspection results from TSB 22-01-023H-2 (DTC P1326 – Engine Bearing Inspection/Engine Replacement) or the latest version.

This TSB references the Op codes to use for claim submission and the Parts required based on the vehicle’s inspection results from TSB 22-01-023H (DTC P1326 – Engine Bearing Inspection/Engine Replacement) or the latest version.

Hyundai has settled a class action lawsuit that alleges that certain Hyundai and Kia Class Vehicles (defined below) contain defective ZF-TRW airbag control units (“ZF-TRW ACUs”) that are vulnerable to a condition called electrical overstress, which may cause the vehicles’ airbags and other safety features to fail during a collision. Hyundai has not been found liable for any claims alleged in the lawsuit. Instead, Hyundai reached a voluntary settlement (referred as “the Settlement” or “the proposed Settlement”) to avoid lengthy litigation and provide relief to people who own ed or leased Class Vehicles in the United States and U.S. Territories. Class Members may be entitled to compensation if they submit valid and timely Claims.

A Class Action settlement regarding the TRW Airbag was recently decided. Based on the Class Action, customers are eligible for certain settlement benefits. Impacted vehicles are also noted below. For further information regarding settlement benefits and contacts, please review the corresponding dealer notification. It is available on Hyundaidealer.com under Hyundai Tech Info > Service News.