2022 Hyundai Sonata

RECALL REMEDY FAILURE AND MANUFACTURER COERCION My Certified Pre-Owned 2022 Hyundai Sonata Limited has been held completely out of service at an authorized Hyundai facility since June 2, 2026, due to severe fuel tank expansion under active NHTSA Safety Recall 25V-796 (Hyundai Campaign 286).The dealership confirmed that the defective expanding plastic fuel tank ballooned with enough force to structurally warp and buckle the unibody center floor pan and frame rails. Rather than providing a safe, timely remedy under federal recall guidelines, Hyundai Corporate and the dealership are attempting to coerce me into an unfair, non-statutory "voluntary trade-in" that simply pays off my remaining loan balance ($22,000) while completely wiping out the $9,000 in cash equity ($3,000 down payment and $6,000 in monthly payments) I have invested into the car. Upon rejecting this predatory trade-in offer, the manufacturer immediately threatened an additional 6 to 8-week delay to attempt a massive structural frame and unibody pull, which would bring the total out-of-service time to over 90 to 110 cumulative days. Furthermore, the dealership is actively withholding the internal diagnostic write-ups and structural alignment prints from me. I am requesting that the NHTSA investigate this recall remedy failure. Hyundai is using extreme delays (90+ days) and structural frame threats to force consumers to abandon their financial equity rather than issuing lawful, purchase-price repurchases for vehicles deemed structurally unsafe due to a manufacturing defect. I can't provide any documents as they have refused being able to provide me with any. Was told I would be emailed a copy from the dealership several times and they never end up sending over any information.

NHTSA ID

11754635

Incident

Jun 2, 2026

The contact owns a 2022 Hyundai Sonata. The contact stated that while driving approximately 65 MPH, there was an abnormally loud bang coming from the vehicle. Upon inspection, the contact became aware that the sunroof windshield visor had shattered. The vehicle was taken to a local dealer where it remained for further inspection. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 61,000.

NHTSA ID

11753318

Incident

Jul 26, 2026

Mileage

61,000 mi

The driver's power seat drive cable on the left-hand track rail snapped internally. The motor only advances the right side, causing the seat to twist violently to the left and jam. This mechanical failure occurred prematurely at 9,000 miles. Because the seat framework is structurally compromised and twisting out of alignment, it poses a severe occupant safety hazard in a collision. And interferes with positioning the seat to operate the vehicle safely. The dealer has inspected the complaint and was able to reproduce the complaint. But did not cover it under warranty. There where no warning signs before the premature failure.

NHTSA ID

11753307

Incident

Jun 16, 2023

The engine on a 2022 Hyundai Sonata developed rod knock at approximately 99,460 miles. The vehicle had been serviced exclusively at an authorized Hyundai dealership for its entire life with 12 documented service visits. What failed: The engine lubrication system. Two prior events at the dealership are documented in the service records: (1) approximately 20,000 miles before the rod knock, a dealership technician damaged the oil filter cap during a service visit, causing an active engine oil leak while the vehicle was being driven. The dealership repaired this at no charge, indicating fault. (2) The dealership placed an oil change reminder sticker in the vehicle specifying an interval that their own service advisor later acknowledged was set incorrectly. The vehicle was brought in approximately 660 miles past that sticker date. Safety risk: Rod knock indicates internal engine bearing failure. The engine continued to be driven at the dealership's instruction ("keep driving, come back if you hear it again") with unresolved internal damage. The knocking sound has since returned, creating risk of sudden engine failure while in operation. Confirmed by dealer: Yes. The rod knock was confirmed by the dealership's technician on the date of the diagnostic visit. The diagnosis noted the engine was low on oil and recommended an oil change, but no repair was performed. Warning lamps/prior symptoms: The engine oil warning light illuminated during the prior oil filter cap leak incident. At the rod knock visit, the knocking sound was the presenting symptom. No oil pressure warning light was noted at that visit. Inspection status: Inspected by authorized Hyundai dealership. Warranty claim was denied by dealership and no response has been received from Hyundai Motor America after formal escalation.

NHTSA ID

11749200

Incident

May 31, 2025

The contact owns a 2022 Hyundai Sonata. The contact received notification of NTHSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11746780

Incident

Jun 26, 2026

The vehicle’s fuel tank system failed catastrophically. The vehicle is currently grounded and has been inspected at the Hyundai dealership service center where it was towed. My safety and the safety of everyone on the road was put at extreme risk due to a severe fire and explosion hazard. Additionally, the defect caused the vehicle to suddenly lose power, sputter, and threaten to stall out while driving on a major interstate, creating an immediate risk of a high-speed rear-end collision. When attempting to add fuel, the pressurized tank forcefully spit gasoline back out of the filler neck, creating an active chemical and fire hazard at a public gas station. I was able to drive it home and called via Hyundai Roadside Assistance to have it towed to an authorized Hyundai dealership service department. On June 15th, 2026, the dealership service technicians officially confirmed the failure, stating that the fuel tank had expanded, the back floor base of the car was melting, and the vehicle was on the verge of exploding.

NHTSA ID

11744661

Incident

Jun 9, 2026

Hyundai Sonata SEL - 2022 Both Leg break and hand break didnt work while driving. its a very severe issue in this model.

NHTSA ID

11741184

Incident

Jan 14, 2026

2022 Hyundai Sonata N Line, VIN [XXX] , purchased August 15, 2025 with low mileage under original manufacturer warranty. Within 3 months, recurring transmission and drivability failures began. Six repair visits since November 2025; 71+ cumulative days out of service within 8 months. Visit 1 (11/24/25, 14,748 mi): Hesitation/failure to accelerate from stop. Could not duplicate. Visit 2 (12/4/25, 14,800 mi): Same concern. Fault codes found; auxiliary pump and relay replaced. Visit 3 (1/19/26, 15,982 mi): Check engine light, jerking. External oil pump leaking; replacement required. Visit 4 (1/30/26, 16,025 mi): Check engine light. TCU update, DCT learning performed; declared resolved. Visit 5 (2/19/26, 16,119 mi): Check engine light returned. Transmission oil pump failed; replaced. Visit 6 (4/14/26, 16,945 mi — OPEN 44+ days): Post-repair lurching, infotainment failure, ongoing jerking. On 5/28/26, the service manager at McDonough Hyundai (McDonough, GA) stated the vehicle likely requires a complete transmission replacement and disclosed approximately 4 additional vehicles at the same dealership with identical unresolved issues. Hyundai Motor America refuses to authorize repairs or Techline escalation unless the dealership confirms the intermittent concern — a structural barrier that prevents warranty resolution. Safety concern: repeated failure to accelerate normally from a stop creates direct risk of rear-end collision or inability to clear intersections. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11740755

Incident

Nov 24, 2025

This bulletin provides information related to a Transmission Control Unit (TCU) software update for some vehicles equipped with an 8-speed wet dual clutch transmission (8WDCT). The software update revises the touch point learning variation, improving drivability and judder symptoms. Some 8WDCTs (indicated by a new part number) received an updated clutch spring. The correct TCU software update must be matched with the correct corresponding 8WDCT hardware, otherwise, drivability concerns may occur. This service procedure should be performed prior to any 8WDCT replacements done for drivability/judder concerns.

Some vehicles may exhibit difficulty starting in cold weather. This bulletin provides the procedure to perform an inspection on the starter magnetic switch for potential freezing and, if necessary, replace the starter magnetic switch (solenoid) assembly.

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 Santa Cruz (NXT), Santa Fe (TMA, MX5A), and Sonata (DN8A) models may require replacement of the 8-speed wet dual clutch transmission (8WDCT) when the vehicle sets one of the high pressure electric oil pump (HP EOP) DTCs listed below. This bulletin provides instructions to replace the 8WDCT.

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).