2017 Hyundai Sonata Plug-In 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 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.

On 12/20/25, the car - a Sonata plug-in hybrid - failed to start. When I pushed the "start" button, the dashboard display lit up w many clearly irrelevant error messages. Each time I pressed start, somewhat fewer error messages blasted toward me, and finally, no response at all. On 12/21/2026, the tow driver said it was the 12-volt battery. He gave us a jump start and we drove a few blocks. However, it failed at the turn lane while waiting for the light to turn. We turned it back on, bought a new battery, had it installed. On 12/29/25, my husband was driving. He turned into the intersection with a traffic light. As he was making the turn, the car simply quit. No warning. The car was dead, and blocking traffic! He pressed the start button to turn off the car, then again to turn it on. He was able to complete the turn and parked on the side of the road. By this time it had a "check engine" light on. He then drove slowly the few blocks back to our house. On 12/30/2025, the car was towed to a local mechanic. He said it threw the code PODE7, "almost certainly for a failed High Voltage battery." It was still under warranty, and we had the car towed to the dealership. After keeping it for 2 or 3 weeks, they confirmed the code and that the control panel needed to be replaced. We finally picked up the car (w new control panel) on 2/20/2026. In the meanwhile, we looked up Hyundai control panel repairs on a reddit forum. We found lots of chatter about it. Turns out it's a recognized problem in Sonata and Ioniq EV and PHEV's! Clearly, a car failing in the middle of an intersection, highway, etc is a safety problem and needs to have repair/replacements made BEFORE THEY HAPPEN!

NHTSA ID

11737182

Incident

Dec 29, 2025

I am reporting a serious safety issue involving a 2017 Hyundai Sonata Plug-in Hybrid (VIN: [XXX] ), originally purchased in California. While driving at approximately 70 mph on a highway, the vehicle suddenly lost all propulsion without warning and rapidly decelerated. This created a dangerous situation with surrounding traffic and put me and my family at risk. I had to quickly maneuver to the shoulder to avoid a potential collision. The vehicle was towed to an authorized Hyundai dealership in Utah, where it was diagnosed with a failure of the high-voltage battery system. I was informed that the battery requires replacement. This type of sudden loss of propulsion at highway speed is extremely hazardous and could result in a crash, injury, or fatality. There were no prior warnings indicating an imminent failure of this severity. Given the safety risk associated with unexpected loss of propulsion, I am concerned this may represent a broader issue affecting similar vehicles. The vehicle is equipped with an interior camera, and video of the incident can be provided if needed. I respectfully request that this issue be investigated as a potential safety defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11734703

Incident

Apr 11, 2026

To the National Highway Traffic Safety Administration, I am filing this formal safety complaint regarding a dangerous engine failure incident involving my 2017 Hyundai Sonata Plug-in Hybrid. Description of Incident: While traveling on CA-85 near Mountain View, California, at approximately 65 miles per hour, the engine suddenly and without warning lost all power. The vehicle began to slow down involuntarily in active highway traffic, creating an immediate and serious risk of rear-end collision. The driver had no ability to maintain safe highway speed or accelerate out of danger. The vehicle had to be towed from the scene to the dealership. There was no warning light or prior indication that engine failure was imminent. The failure was sudden, complete, and occurred at highway speed in heavy traffic conditions. Safety Risk to the Public: This incident represents a significant and ongoing public safety hazard. A sudden, unpredictable loss of engine power at highway speed — with no prior warning — places the driver, passengers, and surrounding vehicles at serious risk of collision. This is not an isolated mechanical inconvenience; it is a life-threatening failure mode. Known and Documented Defects: The 2017 Hyundai Sonata Plug-in Hybrid has been the subject of multiple recalls and class action litigation related to engine defects. My incident is consistent with the known failure patterns documented in those proceedings. Despite this history, Hyundai Motor America has denied my warranty claim, citing missed services — a characterization I dispute, as the vehicle was serviced exclusively at an authorized Hyundai dealership whenever the onboard system indicated service was due, and no technician ever identified or disclosed any engine damage during those visits. Request to NHTSA: I respectfully request that NHTSA: 1. Open or expand an investigation into engine failure incidents in the 2018 Hyundai Sonata Plug-in Hybrid 2. Investigate whether a recall is warranted

NHTSA ID

11725213

Incident

Dec 7, 2025

While driving car stuttered check engine light and check hybrid system flashed. Check engine lights stayed on until getting home. Next day. I scanned and code p0b68 was set.

NHTSA ID

11686903

Incident

Sep 11, 2025

While driving at a high rate of speed propulsion to the vehicle suddenly and without warning ceased, the electric and internal combustion engine were non-responsive (ICE stopped; hybrid motor didn't provide propulsion), the warning light said "Check Hybrid System. Turn off engine" I was put at risk because I was traveling at highway speed and was given no warning before the vehicle shut down. This has occurred nine times, I've reported all to Hyundai, they have had the car in the shop three times, the issue is not fixed. No, despite ODB2 error codes, the car has not shut down while a dealership is driving it. Yes, the vehicle has been inspected multiple times by Hyundai. Yes, always "Check Hybrid System. Turn off engine", in almost all cases the check engine light comes on after that, and in some cases additional lights such as "auto hold". This first occurred in Dec 2023, I was told the car was fixed (it wasn't) and happened again in October 2024. I haven't been able to drive my car since then.

NHTSA ID

11648675

Incident

Oct 23, 2024

While driving the 2017 Hyundai Sonata Plug-In Hybrid, the car will begin to stall, a rapid number of audible beeps will start, the "Check Hybrid System" notification will pop up on the dashboard, and the "Check Engine Light" appears.. The car therefore cannot be driven anymore, and I am forced to pull over to the side. In order to fix the issue temporarily, I need to turn the car off and turn it back on again. Once this is completed, both the "Check Hybrid System" and the "Check Engine Light" disappears and the car can be driven again. An OBD Scanner is unable to find exactly what is going on as the "Check Hybrid System" and the "Check Engine Light" no longer appear. This has happened 4 times now within the span of 3 months. The people at risk are me (the driver), my passengers, and potentially everyone else on the road in my nearby vicinity as the problem occurs. This problem has been confirmed by the dealer in their Hybrid vehicles. This vehicle has not been inspected yet but that is an ongoing process.

NHTSA ID

11579536

Incident

Mar 24, 2024

I was driving the vehicle with 2 other occupants onboard on [XXX] towards US-101. The EPS warning light already came on after entering [XXX] from [XXX], but initially, I didn't think it was much of an issue. As I merged to the right lane in preparation of entering the highway, the steering began to feel very stiff, so I immediately made a right turn into a local street when there was a little bit of steering left. As soon as I pulled over, the steering locked up completely, and both the EPS warning light and the dash display's lane-departure system warning were activated. Luckily no other vehicle or humans were endangered at the time. I put the car into park and powered it off. When I powered it back on again several minutes later, the issue resolved itself and I was able to continue driving with normal steering, and steering remained normal after several power on/off cycles which included both local and highway driving. Come to think of it, ~3 months before this incident happened, I already noticed occasional stuttering of the steering wheel and humming of the EPS assembly when the car is stationary or at low speed. I took the car to a third-party repair shop on the next day since the Hyundai dealership appointment is a week away at the earliest. They ran diagnosis before telling me that the steering sensor in the EPS motor assembly failed, and this happened very frequently for 2017 Sonata Plug-in hybrids. This happens so often, apparently, that Hyundai issued service bulletin [XXX], but this very much looks like a recall to me, as when the system fails, steering is lost completely, and could cause great harm to myself as well as the occupants onboard, not to mention other vehicles around me. I was lucky that it happened before I entered the highway and also had a place to pull over. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11568255

Incident

Jan 25, 2024

Vehicle lost power in freeway. Complete power failure. Early crashed into. Vehicle coasted to off ramp and towed away.

NHTSA ID

11567254

Incident

Nov 27, 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.

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.

Some vehicles may exhibit a loss of connectivity or interruptions in the middle of using Bluelink Service functions. This may be due to an irregular disconnection on Verizon’s communication network. Follow the procedure in this TSB to reestablish the connection via the AVN pinhole reset method.