2014 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.

The contact owns a 2014 Hyundai Tucson. The contact stated that while driving 40 MPH, the vehicle started making an abnormal ticking sound. While accelerating, the sound level increased. The contact stated that the failure was related to the engine warranty extension TXXM. An independent mechanic was contacted and determined that there was an internal failure with the engine. The fluid levels were topped off; however, the sound continued while driving. The vehicle was towed to the local dealer and the dealer declined to replace the engine due to incomplete updates. The warranty was not transferred. The vehicle was not repaired. The vehicle was purchased from Enterprise Rental Car, and the warranty was not transferred to the owner. The manufacturer was contacted and opened a case. The failure mileage was approximately 134,000.

NHTSA ID

11732367

Incident

Feb 25, 2026

Mileage

134,000 mi

My truck started knock and losing power as I drove it. I took it to get serviced put the machine same is was a recall on the engine. I took it to the Hyundai dealership with in 2 weeks he said it was rejected by Hyundai to replace my motor. I service my car but they said I didn't. If it's a recall and not my fault.

NHTSA ID

11719937

Incident

Feb 6, 2026

I AM THE ORIGINAL OWNER OF THIS 2014 HYUNDAI TUCSON. IN AUGUST 2025 I NOTICED THAT THE REAR PASSENGER DOOR LOCKS SEIZED. THIS MEANT THE DOOR COULD NOT BE OPENED FROM THE INSIDE, OUTSIDE OR REMOTELY. THIS PRESENTED A SERIOUS SAFETY HAZARD IN THE EVENT OF A COLLISION , OVERTURN , FIRE OR FLOOD. nO PASSENGER COULD EXIT, AND NO RESCUER COULD OPEN THE DOOR. I NOTIFIED HYUNDAI CUSTOMER SERVICE AND THEY GAVE ME A CASE #[XXX], BUT SAID THERE WAS NOTHING THEY COUD DO AS NO RECALL HAD BEEN MADE. HOWEVER THEY DID RECALL THE 2015 HYUNDAI TUCSON FOR THE SAME DEFECTIVE PART. SO THEY ARE AWARE OF THIS DEFECT AND HAZARD. SINCE HUNDAI REFUSED TO FIX THIS, I INSTRUCTED MY LOCLA MECHANIC TO REPLACE THE LOCKING MECHANISM AT A COST OF $649.80. BILL ATTACHED. I ASK THAT H;YUNDAI REIMBURSE ME AS THIS WAS A LIFE THREATENING DEFECT. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11710366

Incident

Aug 15, 2025

The contact owns a 2014 Hyundai Tucson. While the contact's wife was driving at an undisclosed speed, several unknown warning lights illuminated, and the vehicle lost motive power. The contact's wife was able to coast the vehicle to the shoulder of the roadway. The vehicle was towed to an independent mechanic, where it was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The contact was advised to have the vehicle towed to the dealer. In addition, the contact was informed of Campaign 953 (Extended Warranty on the Engine). The vehicle was later towed to the dealer, where it was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. In addition, the contact was informed of Campaign 953 (Extended Warranty on the Engine). The manufacturer was made aware of the failure by the dealer. The manufacturer initially agreed to a good-faith repair. The manufacturer declined the good-faith repair because the Campaign 953 requirement was not performed. The contact had not received information on Campaign 953. The failure mileage was approximately 130,000.

NHTSA ID

11705061

Incident

Nov 12, 2025

Mileage

130,000 mi

On 10/13/25, I was driving on a state hwy & lost all power. All of my warning lights came on. I managed to pull into a driveway & when I tried to start it, puffs of smoke were coming from under the hood. I got it to my mechanic & he said my starter was burnt up. He replaced the starter & discovered that my engine is seized up. It was a scary incident especially driving on a busy state highway. It put my life & others lives in danger. There were no warning lights on prior to this. I acquired the vehicle in February from a car lot. I have had it serviced regularly.

NHTSA ID

11699668

Incident

Oct 13, 2025

The contact owns a 2014 Hyundai Tucson. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to coast to the shoulder of the roadway, where the vehicle was able to be restarted. The vehicle returned to normal functionality, but the failure became a regular occurrence. The low oil warning light was illuminated. The vehicle was taken to the dealer, and an oil consumption test was performed. The contact stated that after performing the oil consumption test, the contact was informed that the vehicle was consuming over 1 quart of oil per 1,000 miles driven. The contact was advised by the dealer to continue driving the vehicle for another 1,000 for further evaluation. The manufacturer was notified of the failure, and a case was filed. The failure mileage was 110,000.

NHTSA ID

11690356

Incident

Jan 15, 2024

Mileage

110,000 mi

The engine experienced catastrophic failure. A piston punctured the engine block, likely due to failure of the connecting rods, an issue known to be associated with the recalled Theta II engine. The engine is still in the vehicle and available for inspection upon request. We were scared and felt seriously endangered during the incident. The engine failed suddenly while we were driving on a busy highway. After a loud clunk, the vehicle immediately lost acceleration and would not respond to throttle input. We had to quickly pull over onto the shoulder while traffic sped past us at high speeds. The sudden loss of power in fast-moving traffic put us at serious risk of being rear-ended or causing an accident. It was a frightening experience that could have resulted in injury or worse. An independent mechanic inspected the vehicle and confirmed there is a hole in the engine block caused by a piston. We brought the vehicle to a Hyundai dealership for further inspection. Still, their communication has been poor, and they have not yet confirmed whether they acknowledge the issue or its relation to the Theta II engine recall. Our independent mechanic has inspected the vehicle and is currently with a Hyundai dealership for inspection. It has not been checked by police or insurance representatives. No third-party inspector has been involved beyond the dealer and mechanic. There were no warning lights, error messages, noises, or performance symptoms before the failure. The engine failure was sudden and occurred without any prior indication of a problem.

NHTSA ID

11683104

Incident

Jun 9, 2025

The high pressure fuel line began leaking gasoline after warrantee replacement of engine.

NHTSA ID

11682766

Incident

Aug 11, 2025

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.

In response to this trend, we engineered a software upgrade that addresses the social media theft method and made it available to owners of eligible models free of charge at authorized Hyundai dealers since early 2023. In addition to the anti-theft software, we’ve developed a new zinc-reinforced ignition cylinder protector hardware upgrade that can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because your Hyundai vehicle with the VIN listed above (“Subject Vehicle”) was not factory-equipped with an engine immobilizer and was previously eligible for the software upgrade, you are now eligible until March 31, 2027 to have the ignition cylinder protector installed — if you request it — at no cost to you through an authorized Hyundai dealership.

Upon customer's request ONLY, the Technical Service Bulletin (TSB) 25-01-089H provides the service procedure for installation of a key cylinder reinforcement protector assembly and two anti-theft decals on the front windows. This repair procedure is being provided in addition to the previous Anti-Theft software provided under Service Campaign 993 (TSB 24-01-009H-1).