2023 Hyundai Tucson Hybrid Problems

I am reporting a critical Exhaust Gas Recirculation (EGR) valve failure on my 2023 Hyundai Tucson Hybrid. The failure resulted in an immediate loss of engine power, reduced vehicle performance, reduced fuel efficiency, and the vehicle entering limp mode while driving, creating a significant safety hazard in traffic. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) were confirmed during diagnostic inspection. Root Cause: The component failure is directly linked to an internal short circuit in the EGR valve assembly, caused by solder flux contamination during manufacturing. Manufacturer Response & Escalation Denial: When contacting Hyundai regarding this failure, I was informed that my vehicle’s VIN is "not included in Safety Recall 260" (NHTSA Campaign 24V-308). I formally escalated this claim to Hyundai Corporate, but my request for reimbursement and coverage was explicitly denied on the grounds that my VIN falls outside the designated recall parameters. However, this exact failure mode, part assembly line, and manufacturing defect (solder flux contamination) are identical to the safety defect described in Recall 260 as well as Hyundai Service Campaign 9B3. Hyundai is restricting coverage based on narrow VIN manufacturing windows despite identical, defective parts being installed across non-recalled vehicles. Because a sudden EGR failure causes unexpected loss of power while traveling in traffic, and because Hyundai Corporate has refused to cover this out-of-pocket repair, I am requesting that NHTSA investigate this issue and compel Hyundai to expand the scope of Recall 260 to protect affected owners and mandate reimbursement for out-of-pocket repair costs.

On June 3, 2025, I experienced a terrifying and dangerous incident while driving my 2023 Hyundai Tucson Hybrid on a three-lane road at approximately 50 mph. Without any warning, the gas pedal became completely unresponsive, and the car abruptly decelerated from 50 to 20 mph. This sudden loss of acceleration was incredibly frightening, especially with vehicles close behind me that nearly collided with mine. There were no warning lights or check engine alerts. Fortunately, I was able to safely cross all lanes and pull over before having the vehicle towed to a local Hyundai dealership. I shudder to think what might have happened if this had occurred on a highway at higher speeds. This is not the first time I’ve experienced serious issues with this vehicle. In February 2024, at about 17,000 miles, I received an urgent alert recommending a system check. At that time, the car was revving while idle and would occasionally lurch at low speeds. The dealership had difficulty diagnosing and resolving the issue, and my vehicle remained in the shop for over a month before they ultimately replaced the oxygen sensor. Since then, the car has continued to lurch intermittently — for example, when backing out of a parking space or in stop-and-go traffic. In fact, approximately 10 minutes before the June 3 incident, the vehicle lurched several times while moving slowly in traffic. When the car began to lose speed during the most recent incident, I pressed the gas pedal all the way down, but it failed to respond at all. I believe the current issue may be related to the unresolved problems from last year and represents a significant and recurring safety concern. I’ve also read in Tucson owner forums that other drivers have experienced similar issues, suggesting this may be part of a broader, systemic defect. At this point, I do not feel safe driving this vehicle. I truly believe this car is a lemon. This vehicle is still at the dealership, but they have not given me any updates yet.

Vehicle exhibits a dangerous 2-to-3-second delay/total loss of accelerator response at low speeds or rolling stops (5–15 mph). When stepping on the gas pedal to pull into traffic or make a turn, the vehicle hesitates completely before engaging power, even when the pedal is fully depressed. This creates an extreme crash risk when entering oncoming traffic or merging.

On June 3, 2025, I experienced a terrifying and dangerous incident while driving my 2023 Hyundai Tucson Hybrid on a three-lane road at approximately 50 mph. Without any warning, the gas pedal became completely unresponsive, and the car abruptly decelerated from 50 to 20 mph. This sudden loss of acceleration was incredibly frightening, especially with vehicles close behind me that nearly collided with mine. There were no warning lights or check engine alerts. Fortunately, I was able to safely cross all lanes and pull over before having the vehicle towed to a local Hyundai dealership. I shudder to think what might have happened if this had occurred on a highway at higher speeds. This is not the first time I’ve experienced serious issues with this vehicle. In February 2024, at about 17,000 miles, I received an urgent alert recommending a system check. At that time, the car was revving while idle and would occasionally lurch at low speeds. The dealership had difficulty diagnosing and resolving the issue, and my vehicle remained in the shop for over a month before they ultimately replaced the oxygen sensor. Since then, the car has continued to lurch intermittently — for example, when backing out of a parking space or in stop-and-go traffic. In fact, approximately 10 minutes before the June 3 incident, the vehicle lurched several times while moving slowly in traffic. When the car began to lose speed during the most recent incident, I pressed the gas pedal all the way down, but it failed to respond at all. I believe the current issue may be related to the unresolved problems from last year and represents a significant and recurring safety concern. I’ve also read in Tucson owner forums that other drivers have experienced similar issues, suggesting this may be part of a broader, systemic defect. At this point, I do not feel safe driving this vehicle. I truly believe this car is a lemon. This vehicle is still at the dealership, but they have not given me any updates yet.

1. Sometimes vehicle does not start. Only starts if battery reset button pushed. 2. Sometimes vehicle while moving has delayed braking after juddering. Only stops when car stopped and restarted. 3. Sometimes vehicle while moving suddenly revs, RPMs spike until car stopped and restarted. Engine revs but does not shoot forward. 4. Spookiest of all, while moving car suddenly stops accelerating. Pedal on the floor and it is coasting to a stop. When car stopped, and turned off, then it will work. Had we been on the interstate we would have died, These incidents were sporadic and occurred on and off during the month of April and May. Each of the above occurred numerous times to different drivers. Service at two locations were unable to ID. We sold the moving death trap to one of the Hyundai dealers who could find no mechanical problems with the vehicle. The vehicle was terrifying to drive. There are other reports on this vehicle of these issues ... which appear to be electronic. Hyundai has good engineers. They know what is causing this and simply do not want to replace a very expensive but obviously failing electronic control module.

As I was (very slowly) pulling into a parking place at a park near my home and I was braking to come to a full stop, the car suddenly lurched forward, jumped the parking place barrier, and hit a tree. The front end of the car was badly damaged and the airbag opened. I sustained injuries to my left hand and my chest, though nothing was broken. The car was towed to a body shop, where it has been declared not reparable. Photos of the car at the scene are attached. This accident seems to be consistent with reports/recalls of the Hyundai Elantra of unintended acceleration when releasing the brake. We did talk to police shortly after the accident but we are unsure if they filed a report.

I am reporting a critical Exhaust Gas Recirculation (EGR) valve failure on my 2023 Hyundai Tucson Hybrid. The failure resulted in an immediate loss of engine power, reduced vehicle performance, reduced fuel efficiency, and the vehicle entering limp mode while driving, creating a significant safety hazard in traffic. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) were confirmed during diagnostic inspection. Root Cause: The component failure is directly linked to an internal short circuit in the EGR valve assembly, caused by solder flux contamination during manufacturing. Manufacturer Response & Escalation Denial: When contacting Hyundai regarding this failure, I was informed that my vehicle’s VIN is "not included in Safety Recall 260" (NHTSA Campaign 24V-308). I formally escalated this claim to Hyundai Corporate, but my request for reimbursement and coverage was explicitly denied on the grounds that my VIN falls outside the designated recall parameters. However, this exact failure mode, part assembly line, and manufacturing defect (solder flux contamination) are identical to the safety defect described in Recall 260 as well as Hyundai Service Campaign 9B3. Hyundai is restricting coverage based on narrow VIN manufacturing windows despite identical, defective parts being installed across non-recalled vehicles. Because a sudden EGR failure causes unexpected loss of power while traveling in traffic, and because Hyundai Corporate has refused to cover this out-of-pocket repair, I am requesting that NHTSA investigate this issue and compel Hyundai to expand the scope of Recall 260 to protect affected owners and mandate reimbursement for out-of-pocket repair costs.

Vehicle exhibits a dangerous 2-to-3-second delay/total loss of accelerator response at low speeds or rolling stops (5–15 mph). When stepping on the gas pedal to pull into traffic or make a turn, the vehicle hesitates completely before engaging power, even when the pedal is fully depressed. This creates an extreme crash risk when entering oncoming traffic or merging.

VIN: [XXX] Component Failed: Panoramic Sunroof Type of Failure: Spontaneous Explosion/Rupture from the Inside Occurred: Saturday [XXX] at [XXX] Road Conditions: Smooth Road, Clear Day (No Rain or Hail), Temperature mid 80’s degrees Fahrenheit, No Other Cars on Road. Milage on Car: 19640 Initial Event: Driving on the road when passengers hear what sounded like a gunshot (no firearms present in the vehicle). Pulled over to the side of the road to check tires. Tires were okay but noticed the sunroof had spontaneously shattered. Initial Event Photo Indicates Rupture occurred from the inside of the vehicle and not an external force, but there was no access from the inside of the vehicle as the additional fabric roof prevented shrapnel from entering the vehicle. The glass continued to crumble as the driver returned the vehicle to the house for safety concerns. Patterson Hyundai dealer in Tyler, Texas, tried to submit warranty claim and subsequent appeal, but Manufacturer refuses to own manufacture defect. Drivers contacted glass repair companies in the area, and companies explained they had seen this occur several times before. Evidence: Initial Event Photo Indicates Rupture occurred from the inside of the vehicle and not an external force. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The windshield had a minuscule chip at the edge and it developed into a big crack. It seems like product defect and maybe dangerous.

I am reporting a critical Exhaust Gas Recirculation (EGR) valve failure on my 2023 Hyundai Tucson Hybrid. The failure resulted in an immediate loss of engine power, reduced vehicle performance, reduced fuel efficiency, and the vehicle entering limp mode while driving, creating a significant safety hazard in traffic. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) were confirmed during diagnostic inspection. Root Cause: The component failure is directly linked to an internal short circuit in the EGR valve assembly, caused by solder flux contamination during manufacturing. Manufacturer Response & Escalation Denial: When contacting Hyundai regarding this failure, I was informed that my vehicle’s VIN is "not included in Safety Recall 260" (NHTSA Campaign 24V-308). I formally escalated this claim to Hyundai Corporate, but my request for reimbursement and coverage was explicitly denied on the grounds that my VIN falls outside the designated recall parameters. However, this exact failure mode, part assembly line, and manufacturing defect (solder flux contamination) are identical to the safety defect described in Recall 260 as well as Hyundai Service Campaign 9B3. Hyundai is restricting coverage based on narrow VIN manufacturing windows despite identical, defective parts being installed across non-recalled vehicles. Because a sudden EGR failure causes unexpected loss of power while traveling in traffic, and because Hyundai Corporate has refused to cover this out-of-pocket repair, I am requesting that NHTSA investigate this issue and compel Hyundai to expand the scope of Recall 260 to protect affected owners and mandate reimbursement for out-of-pocket repair costs.

1. Sometimes vehicle does not start. Only starts if battery reset button pushed. 2. Sometimes vehicle while moving has delayed braking after juddering. Only stops when car stopped and restarted. 3. Sometimes vehicle while moving suddenly revs, RPMs spike until car stopped and restarted. Engine revs but does not shoot forward. 4. Spookiest of all, while moving car suddenly stops accelerating. Pedal on the floor and it is coasting to a stop. When car stopped, and turned off, then it will work. Had we been on the interstate we would have died, These incidents were sporadic and occurred on and off during the month of April and May. Each of the above occurred numerous times to different drivers. Service at two locations were unable to ID. We sold the moving death trap to one of the Hyundai dealers who could find no mechanical problems with the vehicle. The vehicle was terrifying to drive. There are other reports on this vehicle of these issues ... which appear to be electronic. Hyundai has good engineers. They know what is causing this and simply do not want to replace a very expensive but obviously failing electronic control module.

1. Sometimes vehicle does not start. Only starts if battery reset button pushed. 2. Sometimes vehicle while moving has delayed braking after juddering. Only stops when car stopped and restarted. 3. Sometimes vehicle while moving suddenly revs, RPMs spike until car stopped and restarted. Engine revs but does not shoot forward. 4. Spookiest of all, while moving car suddenly stops accelerating. Pedal on the floor and it is coasting to a stop. When car stopped, and turned off, then it will work. Had we been on the interstate we would have died, These incidents were sporadic and occurred on and off during the month of April and May. Each of the above occurred numerous times to different drivers. Service at two locations were unable to ID. We sold the moving death trap to one of the Hyundai dealers who could find no mechanical problems with the vehicle. The vehicle was terrifying to drive. There are other reports on this vehicle of these issues ... which appear to be electronic. Hyundai has good engineers. They know what is causing this and simply do not want to replace a very expensive but obviously failing electronic control module.

Our 2023 Hyundai Tucson Hybrid developed an issue with the forward radar. At speed, the car produces a warning ding and then a warning message is displayed stating, "Critical Forward Safety functions are limited. Radar blocked." If the adaptive cruise control is engaged at the time of the warning, it immediately disengages, forcing the driver to quickly respond. If there is a vehicle in the adjacent lane to the right, the automatic braking may at times activate. It happens rain or shine, in good or inclement weather. We have cleaned the areas of the sensors without effect. One dealership has evaluated the vehicle twice and a second dealership once but we have been informed that there was no defect identified. I believe this issue to be a serious safety defect.

The car was purchased in June 2023. The left turn signal malfunctioned a minimum two times while operating the car. The last occurrence was in Nov 2023.There was no symptom of the problem prior to its first appearance. The instrument panel confirmed a message that it should be checked. The car was taken in and inspected, December 2023. The service center did not find the problem.