2015 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.

We have a 2015 Hyundai Tucson that we bought brand new. It has 80k miles on it. The car started using oil about three years ago. The dealer recommended replacement of the catalytic converter, which we did. The car continued to use oil, and the dealership had us replace the catalytic converter two more times, so three times total. Now the problem is occurring again and they are recommending replacement of the catalytic converter for a FOURTH time. We have filed a claim with the manufacturer and have been going in circles with the dealership for months. It is our position that the repeated catalytic converter failure is caused by an underlying motor issue, which should be covered by the manufacturers warranty, but the dealer treated the symptoms instead and waited for the warranty expiration. This car is owned by my father, an [XXX] disabled veteran. He bought this car thinking it would be a safe and reliable vehicle for him to drive into his retirement years. Instead, Hyundai is repeatedly making him pay to replace the same part when it is clearly not resolving the oil consumption issue. He is being taken advantage of. Hyundai should honor their warranty. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11755592

Incident

Sep 1, 2024

While driving on a US highway, the check engine light illuminated and the vehicle lost the ability to start/run normally, requiring the vehicle to be pulled off the road and towed to an authorized Hyundai dealership. Dealer diagnostic testing found the engine failed a bearing/performance test, consistent with connecting rod bearing wear. This failure mode — Check Engine light, DTC P1326, abnormal noise, or a no-crank/no-start condition caused by connecting rod bearing wear — is described in the manufacturer's own internal dealer service bulletin covering an engine warranty extension program for multiple engine families (Theta II MPI and Nu GDI engines) across several model years and vehicle lines. That bulletin acknowledges the failure as a known condition and extends coverage to 15 years/150,000 miles for original and subsequent owners. The failure occurred suddenly and without warning while the vehicle was in active use on a highway, creating a stall/loss-of-power hazard in moving traffic — the vehicle could not be restarted at the roadside. The dealership's own multi-point inspection performed shortly after intake confirmed engine fluid levels and oil grade were within normal range, indicating the failure was not attributable to a lack of lubrication at the time of failure. Despite this, the manufacturer denied warranty coverage for the repair, citing an inability to produce maintenance receipts for a prior period, even though the dealership's own inspection findings do not support a maintenance-related cause. This report is submitted because of the safety hazard posed by unwarned loss of engine power/starting capability while driving, and because this failure pattern appears consistent with a defect the manufacturer has already acknowledged for closely related engine platforms, raising the question of whether additional vehicles with this engine design should be included in that existing warranty/defect campaign.

NHTSA ID

11751791

Incident

Jun 21, 2026

The contact owns a 2015 Hyundai Tucson. The contact stated that while driving at 50 MPH, the vehicle stalled without warning. The engine turned over but failed to restart. The contact related the failure to NHTSA Campaign Number: 22V056000 (Service Brakes, Hydraulic). The vehicle was towed to an independent mechanic shop and then to a local dealer, where it was diagnosed that the engine seized; however, the vehicle was not repaired. The dealer advised that there was no warranty coverage. The Better Business Bureau was contacted and informed that the warranty had expired. The manufacturer was contacted, and a case was filed, but a request for repair coverage was declined due to a failure to have the recall remedy completed; however, both the contact and the previous owner were unaware of the recall. The failure mileage was approximately 118,000.

NHTSA ID

11749344

Incident

Apr 1, 2026

Mileage

118,000 mi

My 2015 Hyundai Tucson with the 2.4L engine developed a loud engine knocking sound while driving. The knocking became worse and the vehicle became unsafe to drive due to the possibility of sudden engine failure. The vehicle is currently at a Hyundai dealership and has been there for over a month. The dealership denied the warranty claim stating that a different engine component failed instead of the connecting rod bearing. This engine is part of the known Theta II engine defect issue that has caused engine failures in many Hyundai vehicles. A sudden engine failure while driving could result in loss of power, difficulty steering or braking, and could increase the risk of a crash. I am filing this complaint because the engine failure symptoms match the known defect pattern, and the vehicle may be unsafe if the issue is not properly addressed. Hyundai Tucson with 113,000 miles and failing engine. I’ve been told repairs have amounted to $10,000. I was told my car has severe engine failure and must be replaced by Hyundai of the shoals in Tuscumbia, AL. Engine failure is dangerous as a fire may start from a metal piece and also loss of control of vehicle is possible. Hyundai has denied warranty as they say the exact part in theta 2 engine settlement is not failing. I have had to complete recalls on this car since the first payment I made on it. The engine knocking began a month ago and that’s about how long the dealership has had my car.

NHTSA ID

11728702

Incident

Mar 16, 2026

On March 13, 2026, I was operating my 2015 Hyundai Tucson when the steering locked up, causing me to crash into a tree head-on. In the course of this head-on crash, my airbags failed to deploy. As a direct result of my airbags not deploying in a serious car crash, my head hit the steering wheel, causing a confirmed concussion diagnosis of Post Traumatic Headache and Post Concussion Syndrome in a hospital emergency room. There were no lights or symbols on the dashboard prior to the accident. My car had a prior repair for a front end collision in a body shop and a replacement of the engine in a Hyundai dealership prior to the accident. My car is currently in a tow yard. There has been no inspection of my car by the manufacturer. I have since discovered that there are a number of complaints filed with the National Highway Traffic Safety Administration ("NHTSA") from other Hyundai Tucson owners for the model years 2005, 2006, 2007, 2012, 2013, 2019, and 2023 complaining of the same defect in their Hyundai Tucsons – the failure of the airbags to deploy in serious car accidents. I believe this represents a systemic safety defect in the Hyundai Tucson airbag system that has not been addressed for the 2015 model year. This failure put my safety at serious risk and resulted in significant injuries that could have been prevented had the airbag system functioned as designed.

NHTSA ID

11725846

Incident

Mar 13, 2026

On January 7, 2026, shortly after delivery of a used 2015 Hyundai Tucson (VIN [XXX] ), the vehicle experienced immediate mechanical failure while being driven, resulting in sudden loss of power and drivability. Multiple warning lights illuminated on the dashboard at the time of failure. The vehicle became disabled and left the occupants stranded roadside in Fairhope, Alabama. The exact component that failed is UNKNOWN at this time. The failure appears related to the engine, powertrain, fuel/propulsion, and/or electrical systems. The vehicle was not operable after the incident. On January 8, 2026, the selling dealership (Sandy Sansing Nissan, Pensacola, Florida) towed the vehicle back to their dealership. The vehicle has remained in the dealership’s possession since that date and is available for inspection upon request. This sudden failure created a significant safety risk due to loss of propulsion while in traffic and exposure to roadside hazards. The problem has not been independently repaired or evaluated by the consumer. No manufacturer inspection has occurred to the consumer’s knowledge. The dealer has not provided a diagnostic report or repair findings. No warning lights or symptoms were disclosed prior to delivery. The failure occurred almost immediately after delivery. The vehicle was sold and delivered by a licensed dealership. The sale is currently in dispute because the vehicle became disabled almost immediately after delivery due to this safety-related failure. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11714404

Incident

Jan 7, 2026

At the time of engine failure, my husband was on the offramp between 140N and 24N at approximately 8:30pm. This ramp is under construction and narrow, but state troopers stopped and were able to push the car to the side of the road. As it was nighttime, my husband and /or other motor vehicle drivers/passengers could've been seriously injured. The car did not display any warning lights or signals. The car was then towed home and then to Empire Hyundai in Fall River, where it was assessed. It was determined that there were 5 outstanding recalls on the vehicle. Hyundai fixed all, with the exception of Recall #966, which was issued and not repaired PRIOR to my purchasing the vehicle. Hyundai Corporate was contacted by Aaron at Empire Hyundai. They (Corporate) refuses to replace the engine. According to Corporate, this should've been fixed by the independent dealer or owner PRIOR to being sold to me.

NHTSA ID

11712080

Incident

Jan 9, 2026

Driving on interstate for approx 30min and the car stopped accelerating. We safely merged off to the side and the car completely shut off. The car would not start. We put oil in and it started up by engine light was on. We got vehicle towed 1hr back into town. We are lucky no cars were behind us to cause an accident. We are also lucky engine did not catch on fire. This happened completely out of the blue. I get my vehicle serviced regularly and serviced at Hyundai dealerships for major repairs. The engine failed us and is available for inspection. Our claim was denied by Hyundai due to my mileage being 10k over the warranty. However they installed the faulty engine so regardless of mileage this needs to be resolved.

NHTSA ID

11699079

Incident

Oct 25, 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).