2019 Hyundai Sonata

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.

Vehicle stalled in traffic due to recall defect. Manufacturer recall remedy is delayed beyond reasonable timeframe, creating ongoing safety exposure.

NHTSA ID

11755086

Incident

Jul 31, 2026

The contact owns a 2019 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, smoke started coming from the hood and the vehicle was pulled over into a parking space. While opening the hood, the contact saw that fire was coming from the top of the engine. The contact stated that the fire consumed the front of the vehicle, including the windshield and the dashboard. The smoke coming from the vehicle was dark gray and turned black afterwards. The contact called 911, and the Fire Department was able to extinguish the fire. There were no injuries reported. A vehicle parked next to the vehicle was damaged by the flames. The contact's vehicle was not inspected or officially deemed a total loss. The vehicle was towed to an independent mechanic where an oil change had been performed prior to the failure. The mechanic stated that there might have been a high-pressure fuel valve on top of the engine that possibly caused a gas leak, which started the fire. The vehicle was not diagnosed or repaired. The dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 172,000.

NHTSA ID

11752343

Incident

Jul 16, 2026

Mileage

172,000 mi

Driver's side seatbelt retraction mechanism failed without warning. Intentionally brought car to dealer ASAP since it was close to 100,000 miles pointed out. This was serious safety defect dealer refused to repair under warranty.

NHTSA ID

11750832

Incident

Jul 10, 2026

The air bag light suddenly illuminated when turning on my car. My car has around 60k miles. It was previously repaired a few times for a power steering faliure while driving making it hard to stear. I believe that this latest failure is due to a failure of the stearing wheel clock spring or another SRS module. failure.

NHTSA ID

11748085

Incident

Jul 2, 2026

2019 Hyundai Sonata Sport. (Original owner). Problem: Transmission. [XXX] (9,912 miles). Lack of power, vehicle did not move when trying to merge onto freeway. Very unsafe. Also, hesitation and jerking. [XXX] (10,619 miles). Lack of power, hesitation, jerking. Hyundai tech performed TSB, TCU updates, ECU update for knock sensor performance, reset engine & transmission updates. [XXX] (41,332 miles). Harsh shifts, hesitation, jerking, clunk sound, gear grabs, bursts of power, lack of power. Unsafe to drive. February 2, 2026 (41,751 miles). Hyundai tech found leak at case seal. Hyundai replaced transmission. [XXX] rough start, vibration in pedals. March 9, 2026 Hyundai tech found transmission fluid leak at case seal. Hyundai replaced transmission. March 25, 2026 Hyundai service advisor voicemail said, have to submit to Hyundai another transmission replacement because new transmission is not good. Issues shifting in reverse, hard slams, loses gears. [XXX] picked up vehicle from Hyundai service dept. Harsh shifting, hesitation, jerking, clunk sound, gear grabs, bursts of power. Clunk sound in steering wheel when turned back-and-forth. Front end vibration & wobbly. Vehicle unsafe. May 26, 2026. I notified Hyundai Motor America. Case #[XXX]. June 10, 2026 (43,000 miles). Hyundai service dept. informed me of right and left front axle replacement, universal steering joint replacement. Vehicle unsafe. [XXX] (43,000 miles). Test drove car with Hyundai tech. Verified front end vibration & shaking. Vehicle unsafe to drive. Hyundai service manager said that Hyundai should recall the transmissions. To date, my car is still at Hyundai service dept. Hyundai's service manager said that the Hyundai service dept. will have a meeting regarding my car and include Hyundai's service director, etc. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11745802

Incident

Apr 14, 2021

The engine is the component or system failed or malfunctioned, and it is available for inspection upon request. Sudden loss of engine power while driving, including during highway speeds or intersections, increasing the risk of a crash. Engine stalling or failure to accelerate, preventing me from safely maneuvering away from hazards. Overheating events, which resulted in complete engine seizure and an unexpected loss of vehicle control, all which can potentially causing catastrophic incident without warning. To include, the increased risk of collision, especially if the failure occurs during traffic, merging, passing, or emergency situations. It has been reported to CC Transmission Auto Repair and independent service center. It was previously inspected by Hyundai dealer. Check engine light present September 2025.

NHTSA ID

11745390

Incident

Sep 22, 2025

after the car is driven for a while in warm weather, the steering can feel sticky after doing a slight turn doing more than 30 MPH. It takes extra force to return the steering wheel to the straight/neutral position. It acts as though the steering wheel is stuck in this slight turn position. The problem is intermittent but does create a safety hazard with the risk of the car being unable to easily remain in its correct lane position. Symptom summary: Intermittent; Worse in warm weather; happens after small steering inputs; Feels like the wheel is “hung up”.

NHTSA ID

11742988

Incident

Jun 7, 2026

For the past several years, this vehicle has experienced a recurring and unresolved engine malfunction that creates a safety hazard. The problem manifests as follows: Symptoms when check engine light illuminates: • Idle RPM elevation to approximately 1500 RPM (normal idle: 800 RPM) • Sudden unintended forward acceleration when foot is removed from brake pedal • Significantly reduced acceleration performance during normal driving • Vehicle becomes difficult to control safely The malfunction occurs intermittently but follows a consistent pattern. This is not an isolated incident but a recurring defect that has persisted for years. Multiple diagnostic and repair attempts have been unsuccessful: • Coconut Creek Hyundai service center - unable to diagnose [DATE(S)] • Independent mechanics - unable to resolve [DATE(S)] • Issue remains unresolved despite multiple service visits Despite multiple attempts by qualified technicians, the root cause has not been identified and the defect has not been corrected. This malfunction creates a significant safety hazard: • Unintended acceleration increases risk of collision • Reduced acceleration capability limits ability to merge or accelerate safely • Check engine light indicates undiagnosed system failure • Problem is intermittent and unpredictable, making it unsafe to drive I am concerned this may represent a defect pattern affecting multiple 2019 Sonata vehicles. NHTSA should: 1. Investigate whether this represents a defect pattern in 2019 Hyundai Sonata vehicles 2. Determine if a safety recall is warranted 3. Contact Hyundai Motor America to address this systemic issue

NHTSA ID

11738831

Incident

Mar 8, 2023

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. The California Air Resources Board has determined that these vehicles may be releasing air pollutants which exceed Federal and California standards.

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. This bulletin provides instructions for updating the Engine Control Module (ECM) to address this condition.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Some Hyundai vehicles with exterior white paint may exhibit peeling or bubbling on metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. The paint warranty coverage for affected vehicles has been extended to 10 years/unlimited miles from the date of original retail delivery or date of first use and is valid for original and subsequent owners.

Certain Hyundai vehicles with exterior white paint may exhibit peeling or bubbling on metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. The paint warranty coverage for affected vehicles has been extended to 10 years/unlimited miles from the date of original retail delivery or date of first use and is valid for original and subsequent owners. The warranty extension does not apply to any vehicle that has ever been declared a total loss or sold for salvage by a financial institution or insurer or has a branded or similar title under any state’s law.