2010 Hyundai Tucson

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

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.

While driving under normal conditions, the panoramic sunroof glass suddenly shattered without warning. There was no impact from road debris, no prior cracking, and no abnormal use of the sunroof. The failure occurred spontaneously and created a safety hazard due to falling glass and the risk of driver distraction or injury. This vehicle is equipped with the factory panoramic roof that has been the subject of a prior class action lawsuit and Hyundai Technical Service Bulletin 19-BD-007H (Panoramic Roof Moving Glass Warranty Extension, code TXXE). The failure I experienced is consistent with the known defect described in that settlement and TSB. Hyundai extended coverage for this defect to 10 years or 120,000 miles; however, Hyundai has denied assistance because the time limit has expired, even though the mileage remains within the coverage threshold. Given the known defect and safety implications, this failure should be addressed regardless of warranty expiration. This issue presents a safety concern due to sudden glass shattering while driving and should be investigated further.

NHTSA ID

11716644

Incident

Feb 6, 2026

This has been an ongoing problem since I last reported this on February 16, 2025. There’s a clicking noise under my tires and then I can’t stop, my brakes grind and my pedal grinds… all my ABS lights then come on… this has been going on too long!! Since April 20, 2025…. My brakes are GRINDING SERIOUSLY and PROHIBITING me to fully stop at times. I’ve had several near misses… I want them fixed now!! My car is no longer safe!!! Still doing it today @ 12:18pm with mileage of 130,605… please help!

NHTSA ID

11674545

Incident

Apr 20, 2025

On January 26, 2024, at AutoNation, I was requested to bring my 2010 Hyundai Tucson in to replace a part involving my ‘brakes.’ I’m the original owner, since 2021 my brakes would grind at least twice weekly and I was afraid I wouldn’t be able to stop! Then, the AntiLock Brake System lights would just pop up out of nowhere and come on, then my brakes would work. So, I was told I needed a new switch. AutoNation never let me explain any of this, they cut me off anytime I tried to explain it. So, last January 2024, the switch was fixed. I’d prefer NOT to go back there again!! It hasn’t been inspected by anyone. NHTSA may inspect it as soon as you would like. Except now, my ABS lights are basically stuck on. This started back again June 2024. No grinding of my brakes now, I just want them fixed properly.

NHTSA ID

11642987

Incident

Mar 6, 2021

The contact owns a 2010 Hyundai Tucson. The contact stated while driving 40-45 MPH, there was an abnormally loud sound coming from underneath the hood and the temperature gauge fluctuated. The vehicle lost motive power. There was no warning light illuminated. The contact was able to pull to the side of the road. The vehicle was towed to the residence. The contact stated that upon opening the hood, an unknown engine part was fractured, and several unknown parts had detached and were leaning on the driver's side of the vehicle. The local dealer was contacted, and an appointment was scheduled for diagnostic testing. The vehicle was not diagnosed or repaired. Additionally, the contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic); 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 failure mileage was approximately 199,996. VIN tool confirms parts not available.

NHTSA ID

11590400

Incident

May 14, 2024

Mileage

199,996 mi

The contact owns a 2010 Hyundai Tucson. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) however, the part to do the recall repair was not yet available. The dealer was contacted, and the contact was informed that there was no recall associated with the VIN. 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. VIN tool confirms parts not available.

NHTSA ID

11583647

Incident

Sep 22, 2023

The contact owns a 2010 Hyundai Tucson. The contact received notification of NHTSA Campaign Number: 23V651000(Service Brakes, hydraulic ); however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available. The consumer stated that the manufacturer will contact them via email when a remedy for the vehicle is ready.

NHTSA ID

11578309

Incident

Sep 23, 2023

The contact owns a 2010 Hyundai Tucson. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. VIN tool confirms parts not available.

NHTSA ID

11568011

Incident

Sep 22, 2023

The contact owns a 2010 Hyundai Tucson. The contact stated that when she started the vehicle, the driver's side air bag warning light illuminated. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 100,000.

NHTSA ID

11550275

Incident

Aug 14, 2023

Mileage

100,000 mi

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 (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-2 (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.

Hyundai is conducting a campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.