2021 Hyundai Sonata Hybrid

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 vehicle was brought to an authorized Hyundai dealer to have Service Campaign TBH and 94B completed. These campaigns were explicitly designed to prevent known mechanical defects (cracked EHRS assemblies and high-voltage battery errors). The software patches failed to protect the vehicle. The physical hardware has now catastrophically failed exactly as predicted by the campaign, resulting in extreme engine overheating and a physically swollen high-voltage battery pack. Hyundai is refusing to cover the cascading physical damage caused by their own failed campaign remedy, leaving me with an active safety and fire hazard. FUEL/PROPULSION SYSTEM" and explicitly state that the vehicle experienced an unchecked thermal event due to an ineffective corporate software update (Campaign TBH / 94B). All documents I have supporting this will not fit in this upload limit.

NHTSA ID

11765311

Incident

Jun 5, 2025

​My Lincoln Nautilus (~9,180 miles) logged 6 "Powertrain Malfunction / Reduced Power" alerts in the [XXX] telematics system between XXX (XXX at 7:59 PM and 8:16 PM; XXX at 1:07 PM and 1:39 PM; XXX at 11:16 PM; and XXX at 10:56 AM). Out of the 6 logged events, I experienced severe loss of motive power during two of them. On XXX, while driving 70 mph on I-95, the vehicle completely lost all propulsion. Coasting without power, I was unable to pull fully onto the shoulder, leaving the car partially stuck in active traffic and narrowly escaping a high-speed collision. Once stopped, the vehicle failed to recognize that it was in Park, causing the electronic parking brake to lock without releasing, which severely delayed towing recovery. The vehicle was towed to a Lincoln dealership in [XXX], whose service department was closed. Upon arrival, the vehicle suffered a complete electrical blackout; the key fob would not unlock the doors, requiring physical key entry. A sales representative provided a jump box, allowing me to start the car, drive back to [XXX], and deliver it to Cavalier Lincoln Ford in [XXX] between 5:00 PM and 7:00 PM on XXX. Cavalier Lincoln Ford stated they could not reproduce the malfunction. The vehicle and its electronic records remain available for inspection upon request. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11765198

Incident

Sep 4, 2026

The vehicle experiences sudden, complete electrical power loss while driving at speed on highways and city streets or on the parking. All digital displays turn off, the engine shuts down, and power-assisted steering and braking are instantly lost without prior warning, presenting an extreme collision risk. The issue first occurred in August 2025 at approximately 48,000 miles and was taken to an authorized Hyundai dealer in Michigan for warranty repair. The dealer held the vehicle for over 30 days but failed to correct the defect. The identical power failure has continued and recently escalated to daily occurrences. A second Hyundai dealer (Pacifico Hyundai, Philadelphia, PA) diagnosed an intermittent open circuit in the engine wiring harness but Hyundai Motor America refuses to repair the vehicle under warranty, claiming 'outside influence' without providing evidence. Driving a hybrid vehicle that randomly cuts all power in live traffic is a life-threatening safety hazard. Hyundai Motor America has failed to rectify this critical safety defect.

NHTSA ID

11755133

Incident

Aug 5, 2026

I purchased this vehicle pre-owned approximately two years ago and have since developed concerns about its reliability, particularly related to the electrical and hybrid systems. In hindsight, I suspect these issues may be part of the reason the original owner traded it in to a CarMax dealer. Shortly after purchasing the vehicle, I began experiencing recurring problems with the 12V battery, including frequent instances requiring battery resets. Interestingly, these issues were significantly less frequent during colder weather. More recently, as temperatures have increased, the problem has worsened considerably. For about the past month, the vehicle loses power and dies immediately after each drive once the ignition is turned off. This situation escalated yesterday when the “Check Hybrid System” warning light signalled while I was driving on a busy road. I had not encountered this warning before, but after researching the issue, I discovered that other Hyundai hybrid owners have reported similar problems. In some cases, these issues have led to dangerous situations, including vehicles shutting off unexpectedly while driving at highway speeds. While I cannot determine the extent of this issue across all Hyundai hybrid vehicles, the frequency of similar reports suggests a systemic defect affecting at least a subset of Hyundai Sonata Hybrid models. Regardless of scale, these battery issues present a significant inconvenience and a serious potential safety concern. I am requesting a formal review of this issue and guidance on potential remedies or corrective action.

NHTSA ID

11745618

Incident

Jun 21, 2026

The vehicle’s 12-volt electrical system repeatedly loses power within about 1 hour of sitting. The car becomes completely unresponsive (cannot unlock or start) and requires use of the built-in 12V battery reset button to restore power. This occurs frequently and makes the vehicle unreliable and potentially unsafe, as the car may become inoperable without warning. This appears to be an electrical system defect or parasitic power drain. The issue has been ongoing.

NHTSA ID

11739503

Incident

May 22, 2026

See attached document for complaint.

NHTSA ID

11730136

Incident

Jan 26, 2026

Owned car since 09/2024 with 64K miles. Battery system (12V/hybrid system) has shut down and died 47 times since 04/2025 - no shut downs before then. Car with ~69K miles at that time. Dealer had car six weeks (05/17 to 07/05/2025) and it died “a number” of times and report that Hyundai claims this is “what the car is supposed to do.” Since 07/05 it has died 12 times just sitting in my driveway or the lot at work. This is NOT normal. Internet blogs show DOZENS of other Hyundai hybrid owners reporting the exact same issue. Car now with 75K miles and under warranty. Dealer will not replace battery system.

NHTSA ID

11679975

Incident

Apr 10, 2025

This is on my 2021 Hyundai Sonata Hybrid Limited - for the 7th time the vehicle has been completely dead and unresponsive. I have had to gain entry to the vehicle using the manual key and press the "jump" button to get the vehicle to start. The Hyundai dealership ran a bunch of battery updates to the 12 volt battery several weeks ago and said that should hopefully fix the issue. Several weeks later on 07/19/2025 the vehicle was dead again. I had to use the key to manually gain entry and jump the car again. The dealership said that the 12 volt battery may need to be replaced and said that it is fully integrated with the hybrid battery system which is covered for 10 years/100K miles whichever comes first. I am still within the warranty period so hopefully Hyundai will fix the issue. From an online search, it appears this is not an uncommon issue with the Hyundai Sonata Hybrid. I am waiting on Hyundai for a fix and for .

NHTSA ID

11676697

Incident

Jul 19, 2025

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.

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.

Some Elantra (CN7, CN7A), Kona (OS, SX2), and Sonata Hybrid (DN8 HEV) vehicles equipped with 2.0L engines may illuminate a warning lamp for DTC P218100 (Cooling System Performance) related to the Integrated Thermal-Management Module (ITM). Follow the service procedure in this bulletin to install a spring onto the thermostat within the ITM, in order to prevent premature opening, and perform an ECU software update on affected vehicles.

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation.

This bulletin provides information related to the changes introduced in the 2025 1st Navigation Map and Software Update. The changes may vary depending on vehicle type, model, and navigation system as described in this TSB.

Certain Hyundai vehicles may exhibit a warning light with Diagnostic Trouble Code (“DTC”) P1BB20 due to a battery over voltage condition.