2016 Hyundai Tucson

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.

Door latch issue. Driver's side door has to be pulled multiple times after unlocking to open from the exterior. Passenger side door latch has become completely inoperable and does not open from the interior or exterior now. To have multiple doors fail at the same time seems like a true design failure / flaw and an inoperable door a true safety hazard.

NHTSA ID

11754445

Incident

Jul 17, 2026

While stopped at a traffic light, the engine began producing a loud metallic clattering and clanking sound, consistent with connecting rod bearing failure (rod knock). There was no prior warning light or indication of this specific failure. When the light changed, the vehicle would not accelerate normally, leaving me stalled in a lane of moving traffic. I was forced to make an emergency turn to get the vehicle out of the way of oncoming and crossing traffic. The engine would not hold an idle afterward and has not run since. The vehicle was towed to a Hyundai dealership, where a service department employee stated by phone that this 1.6L turbocharged engine family has a known, documented history of severe factory defects affecting the connecting rod bearings.

NHTSA ID

11753197

Incident

Jul 22, 2026

All the warning lights in the day lit up. Brake, LDWS, AEB, outside air temperature won’t read and the a/c blows hot. $486 to diagnose at dealer and they state that it’s an electrical issue due to a bad vacuum pump. I can’t get an answer as to whether the vacuum pump safety campaign was completed or not. Dealer wants $1500 to replace.

NHTSA ID

11752545

Incident

Jul 14, 2026

The engine is failing at 128,000 miles. The car is burning so much oil that it is impossible to drive more than 500 miles without the oil running dry. The problem has been inspected by the Hyundai dealership nearest me. The vehicle notified me of the oil issue by illuminating the oil light. The issue started after the turbo failed at 127,000 miles. The turbo was replaced at a cost $3,500 and immediately afterwards the vehicle which previously did not burn oil now does. It doesn't just burn oil it consumes it like a black hole.

NHTSA ID

11749884

Incident

Jun 1, 2026

While driving, the vehicle experienced a sudden and severe loss of motive power accompanied by a loud, catastrophic internal knocking sound from the engine compartment. The vehicle was towed to an authorized Hyundai dealership (Piazza Hyundai of Limerick), where a certified diagnostic technician confirmed a severe internal connecting rod bearing failure (rod knock). This sudden engine failure creates a significant highway safety hazard due to the immediate loss of acceleration and power steering/brake assistance if the engine completely seizes while operational. Hyundai has issued widespread safety recalls and a 15-year/150,000-mile extended warranty (TXXM) for this exact failure mode in other engine displacements (such as the 2.0L Nu GDI), yet they have excluded the 1.6L Turbo engine from identical coverage despite it suffering from the exact same manufacturing defect and presenting the same public safety risk.

NHTSA ID

11747780

Incident

Oct 30, 2025

All the door locks and actuators/latches are failing. Hyundai claims there is no recall for it, and the price for one door repair is $1384... This is a safety issue since the passenger in the rear seat could not get out in an emergency!

NHTSA ID

11747224

Incident

Apr 2, 2026

The contact owns a 2016 Hyundai Tucson. The contact stated that while the vehicle was parked, the front passenger’s side door failed to unlatch as needed. The front passenger's side window failed to roll up or roll down. The driver's side rear door failed to unlatch or latch as needed. Additionally, the trunk switch failed to operate as needed. The dealer was made aware of the failures but provided no assistance. The contact was informed that the repairs were not covered under recall or warranty. The contact stated that the vehicle was unsafe to operate. The contact feared being locked inside the vehicle and being unable to exit the vehicle. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure. The failure mileage was approximately 52,000.

NHTSA ID

11747133

Incident

Feb 11, 2026

Mileage

52,000 mi

The contact owns a 2016 Hyundai Tucson. While the contact’s daughter was driving approximately 55 MPH, the vehicle started to lose motive power. The vehicle failed to restart immediately. The vehicle was started after a while; however, the check engine warning light was illuminated. The vehicle was taken to a Goodyear Service Center to be diagnosed. The contact was informed that the engine had seized and needed to be repaired. The dealer was contacted. The manufacturer was not made aware of the failure. The failure mileage was approximately 119,479.

NHTSA ID

11746702

Incident

Jun 18, 2026

Mileage

119,479 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.

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.

In addition to the Anti-Theft software provided under Service Campaign 993 (TSB 24-01-009H-1), a zinc reinforced ignition cylinder protector hardware upgrade is being made available to customers upon request. This supplemental security measure is to be installed at the ignition switch location and provides additional protection against the social media theft method. Vehicles not equipped with an immobilizer during production at the factory are eligible. The repair procedure shall be performed and claimed upon customer request only. Any future repairs to these vehicles in which an installed ignition cylinder protector impacts required parts and/or labor, shall be covered by HMA. Please see TSB 25-01-089H for details.