2020 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.

A/C blower motor fan would stop working. Happened twice within less than a year apart. Upon further inspection, multi fuse wiring overheated and melted, ruining fuse and making A/C stop working during 100+ temperatures outside. Apparently this is a well known issue with this make and model Sonata. Electrical failure.

NHTSA ID

11762639

Incident

Sep 3, 2026

The A/C evaporator core and the core seal needs replacing on 2020 Hyundai Sonata. Car is 6 years old. I already have a confirmed diagnosis with a PPM refrigerant leak tester at the condensate drain line The diagnosis is 100% confirmed. The evaporator is leaking heavily—we pulled 274 PPM at the drain tube and 177 PPM inside the cabin behind the glove box so refrigerent has been leaking out of the vents. My wife and I were getting headaches for no reason. Our AC has failed and this problem was discovered as the issue and I am paying out of pocket to fix something that should not have failed and has leaked out refrigerent.

NHTSA ID

11761990

Incident

Sep 3, 2026

I am submitting a safety complaint regarding a recurring, unresolved electrical defect in my 2020 Hyundai Sonata SEL. The vehicle fails to recognize when the ignition is switched off, leaving core vehicle systems active and causing severe parasitic battery drain that leaves the car immobilized. ​Description of the Problem: ​False "On" Status: After parking, turning off the engine, and exiting the vehicle, the car continues to register as though the ignition is still active/on (accessories, cluster, or vehicle network remain awake). ​ Severe Parasitic Draw: Because the vehicle fails to shut down its electrical circuits, the 12-volt battery repeatedly discharges overnight or while parked for short durations. ​Battery Replacement Did Not Resolve Issue: The 12-volt battery was replaced with a brand-new unit to eliminate typical wear, yet the drain and false "on" behavior persisted immediately. ​ Frequency: The vehicle frequently fails to start, requiring constant jump-starts or roadside assistance to operate. ​Safety Hazard: This defect creates a direct safety risk by repeatedly stranding the driver without warning in public locations, traffic stops, or remote areas. In addition, an electrical system that fails to enter a sleep state creates a potential hazard for component overheating, failure of electronic security and locking systems, or total electrical failure while attempting to restart or operate auxiliary safety equipment. Other Hyundai owners have reported identical issues where the body control modules or ignition logic fail to power down. ​Corrective Action Requested: I request that the NHTSA investigate this electrical shutdown defect across the 2020 Hyundai Sonata model year to identify whether a faulty Body Control Module (BCM), smart key receiver, or ignition switch relay requires a safety recall and software or hardware remediation. Battery replaced on 09/04/2026 Car inspected/diagnosed by Hyundai Dealership on 09/03/2026

NHTSA ID

11761900

Incident

Aug 10, 2026

Parking malfunction. Parked, running car moved itself to reverse and backed up a driveway crossing a dirt road and hitting a fence and post. This car could have hit and severely injured anyone who was in the path while it was reversing on its own. Car was in reverse and all parking sensors were blaring when the car was found minutes later.

NHTSA ID

11759884

Incident

Aug 26, 2026

The reverse camera only shows a black screen and will put drivers in danger while not being able to see behind them while reversing. This needs to be recalled and repaired. Especially in situations where a person is reversing out of a driveway onto a major/busy road. Sometimes it works, but a lot of the time it is just a black screen with the green, yellow, and red lines to indicate how far your wheel is turned. But it doesn’t allow you to actually SEE where you’re backing up into or the cars coming from either side of you while trying to back out. It’s very dangerous and it seems to a be manufacturer’s defect that needs to be addressed by the company itself, since they’re the ones who made and installed the product incorrectly.

NHTSA ID

11758919

Incident

Aug 1, 2024

Blower motor malfunction at night. Smelled something burning. Extremely hot and humid outside. Windows fogged up inside which greatly reduced visibility. Checked the multifuse which controls the ABS, oil pump, cooling fan, & Blower. I discovered a burnt connection on one of the terminals for the blower. This is a huge safety and fire risk and needs to be addressed ASAP!!!! Upon my research, I’m finding several Hyundai Sonata vehicles having this same exact issue. Kia vehicles are being recalled for this same exact issue. Why isn’t the Hyundai Sonata??

NHTSA ID

11758874

Incident

Aug 21, 2026

The driver's power seat track master assembly (Part#88500-L0030) on my 2020 Hyundai Sonata suffered a catastrophic structural failure while operating. The black plastic bracket housing and aligning the electric drive motor fractured. This caused the motor to pull out of alignment, twisting the driver's seat violently sideways and permanently jamming the tracking rails. This is a chronic, repeat safety component failure on this specific VIN. The original factory seat track assembly suffered an identical mechanical failure and was replaced by warranty on 10/3/2023 at 46,369 miles. This second factory replacement unit failed in exactly the same manner on 8/13/2026 at 82,271 miles-lasting only 35,902 miles under normal operating conditions. I weigh 95 pounds. A driver's seat structurally shifting sideways dynamically presents an immediate, severe crash hazard. It instantly alters driver ergonomics, compromises the structural crash-anchoring performance of the seat frame, and potentially restricts pedal access to the brake and accelerator. The manufacturer is actively denying product liability by classifying internal structural breakages of shielded components beneath the cushion as user "damage" rather than an engineering or climate-related material defect. This tracking component must be formally investigated for systemic failure patterns to prevent accidents.

NHTSA ID

11758369

Incident

Aug 13, 2026

The AC/heating blower motor circuit on my 2020 Hyundai Sonata failed intermittently due to extreme electrical resistance overheating and melting the terminal pins inside the engine fuse box. I took it to the dealership and they inspected it said it was out of warranty but it needed part number 18980-09910-FFF and wiring kit 91300L1000-FF to repair at a cost of 780.00 including parts, tax, and labor. This matches the severe design defect acknowledged in Hyundai TSB #25-EE-002H or alternative TSB-24-EEOO-1H. I filed case number 43138757 with Hyundai corporate. For now this just affects my air conditioning. However, the root failure is a known design defect that presents a severe vehicle fire hazard and potential loss of windshield defrosting capability, lights, etc. if the whole electrical system should fail. As you should know the engine bay fuse box (which currently has melted parts) is the "brain" for the car's electrical distribution. It doesn't just power my AC fan; it holds the fuses and relays for the cars fuel pump, engine control module (ECM), headlights, and electronic power steering. If left unfixed and over time as the plastic melts, copper wires will cross and touch each other, causing a massive short circuit. My engine could suddenly cut out and stall while I am traveling at 70 mph on the highway, instantly killing my power steering and power brakes and putting me in extreme danger. Again not to mention the fire hazard this situation is likely to cause. This should be addressed via a mandatory safety recall, so that I don’t have to pay for a known engineering design defect and in case the TBS bulletin fails or further unknown damage has already occurred.

NHTSA ID

11757743

Incident

Aug 18, 2026

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.

Some 2019MY and newer vehicles equipped with a front view camera may illuminate certain warning lights and trigger DTC C272246 fault code for the front camera. In the following cases, the front camera auto-calibration range may be exceeded while driving: • If the front camera is not properly installed and is completely or partially detached. • In case of excessive changes affecting the vehicle's balance (e.g., loading excessively heavy cargo in a specific location of the vehicle, or significant under-inflation of the tires). • Specific road conditions affecting the vehicle's balance (e.g., excessive road crown) This TSB provides instructions on how to service the vehicle when the front camera related warning light(s) are triggered due to system out of calibration (DTC_C272246).

Some Sonata (DN8, DN8A) vehicles may have DTCs P218100, P2181F0, and/or P2181F1 (Cooling System Performance) set in the Engine Control Module, resulting in an illuminated Check Engine warning lamp. Follow the procedure in this TSB to replace the Integrated Thermal Management (ITM) module and update both the Engine Control Module (ECM) and Transmission Control Module (TCM) if applicable. Follow the flowchart in this TSB to update the appropriate modules.

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.