2021 Hyundai Kona Electric Recalls & Complaints

Incident: April 15, 2024 · Filed: October 15, 2026

The contact owns a 2021 Hyundai Kona Electric. The contact stated that since purchasing the vehicle, an abnormal rumble sound was heard that grew progressively louder. Additionally, while accelerating from a complete stop, the vehicle was significantly sluggish. The failure recurred while driving at 30 MPH, requiring the driver to pull over to the shoulder of the road. Upon shutting off and restarting the vehicle, the vehicle returned to normal operation. The vehicle was taken to a dealer, who was unable to duplicate the failure during a test drive. The vehicle was returned to the dealer, who confirmed the failure; however, the contact was informed that the failure was not associated with TSB Number: 22-EV-001H (KONA EV MOTOR RUMBLE NOISE) because the rumble sound was not sufficiently loud. The contact stated that the sound had grown significantly louder. The vehicle was scheduled to be towed to the dealer. The failure mileage exceeded 60,000.

Incident: February 3, 2026 · Filed: February 22, 2026

On February 3, 2026, while driving in a high-traffic turning lane, my Hyundai Kona Electric vehicle suddenly lost propulsion and would not accelerate. The vehicle shut down without warning and could not be restarted. Traffic was building behind me, creating a safety hazard. I felt unsafe due to surrounding vehicles expecting movement, I contacted the police for assistance. The vehicle had to be towed from the roadway. The vehicle was transferred between 3 dealerships before being diagonsed. On February 16, 2026, the issue was diagnosed as a motor position sensor failure affecting the propulsion system. The vehicle has remained inoperable since February 3, 2026, and there is no repair ETA due to parts availability. The vehicle remains at the servicing dealership and is available for inspection upon request. There were no prior warning lamps, dashboard messages, or noticeable symptoms before the sudden loss of propulsion. This incident involved a sudden failure of the vehicle’s propulsion system while operating in active traffic and presented a significant safety concern.

Incident: August 12, 2024 · Filed: August 29, 2025

Potential Fire and safety risk ... The Hyundai Kona Electric Vehicle (EV) has experienced issues with its Integrated Charging Control Unit (ICCU) due to problems with the low-conductivity coolant (BSC-1) used in models produced between 2018 and October 2021. This coolant can crystallize, forming debris that clogs the cooling system, leading to false "Refill Inverter Coolant" warnings and potential overheating risks. A Technical Service Bulletin (TSB 23-01-049H) outlines a recall to flush and replace the coolant with an improved BSC-2 formula to address this issue. However, improper or repeated coolant flushes, if not performed correctly using Hyundai’s specialized equipment and procedures, can leave air bubbles or residual debris in the system, which may impair cooling efficiency and stress critical components like the ICCU, inverter, and electric motor. Repeated coolant flushes, especially when not executed properly, can exacerbate issues by introducing air locks or failing to fully remove crystallized debris, potentially causing damage to the ICCU, inverter, and motor. Air bubbles trapped in the cooling system can reduce heat dissipation, leading to overheating that may degrade the ICCU’s electronics or cause the inverter and motor to operate at unsafe temperatures, risking premature failure. Posts on forums indicate that some vehicles required multiple flushes to clear the warning, with improper flushing sometimes leaving contaminants that continue to trigger sensors or obstruct coolant flow. This underscores the importance of having the procedure done by trained technicians using the correct tools to avoid long-term damage to these sensitive components.

Incident: November 6, 2024 · Filed: August 29, 2025

File with NHTSA now please!!!! What do you have to lose??? If anything If they do an investigation we are safe post warranty. Report a Vehicle Safety Problem, Equipment Issue | NHTSA [XXX] The Hyundai Kona Electric Vehicle (EV) has experienced issues with its Integrated Charging Control Unit (ICCU) due to problems with the low-conductivity coolant (BSC-1) used in models produced between 2018 and October 2021. This coolant can crystallize, forming debris that clogs the cooling system, leading to false "Refill Inverter Coolant" warnings and potential overheating risks. A Technical Service Bulletin (TSB 23-01-049H) outlines a recall to flush and replace the coolant with an improved BSC-2 formula to address this issue. However, improper or repeated coolant flushes, if not performed correctly using Hyundai’s specialized equipment and procedures, can leave air bubbles or residual debris in the system, which may impair cooling efficiency and stress critical components like the ICCU, inverter, and electric motor. Repeated coolant flushes, especially when not executed properly, can exacerbate issues by introducing air locks or failing to fully remove crystallized debris, potentially causing damage to the ICCU, inverter, and motor. Air bubbles trapped in the cooling system can reduce heat dissipation, leading to overheating that may degrade the ICCU’s electronics or cause the inverter and motor to operate at unsafe temperatures, risking premature failure. Posts on forums indicate that some vehicles required multiple flushes to clear the warning, with improper flushing sometimes leaving contaminants that continue to trigger sensors or obstruct coolant flow. This underscores the importance of having the procedure done by trained technicians using the correct tools to avoid long-term damage to these sensitive components. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Incident: June 27, 2025 · Filed: August 2, 2025

Manufacturing defect ... Took it in 4 times for "refill inverter coolant" warning . They had a campaign ' tried by couldn't get the light to go away . It was their first time ever performing this on an EV at Kerry hyundai alexandria . Now TD EV in mason Ohio is confirming my inverter failed as a direct result of the poor flushes and poor manufacturing. I am seeking for hyundai to cover all related costs. I haven't had my vehicle for over a month . It's out of warranty 'however this was a known issue they issued a campaign for 'and then couldn't fix the issue after 4 or 5 tries and 2 different hyundia dealers . All work performed will be listed at Kerry hounding in alexandria KY and Jefferson wyler hyundai cincinnati Ohio.

Incident: July 4, 2025 · Filed: July 19, 2025

Hyundia has had my car in for the SAME recall 4 to 5 times . 6 total weeks this time around. The ""refill inverter coolant" light kept coming back on . The last time I got it home it had more issues than when I took it in and wouldn't even catch a charge . (EV) They fried my compassitor trying to fix the inverter coolant recall . I then took had to pay 450 for a diagnostic ' (Kerry hyundai alexandria) They said electric motor is bad and will cost 8000 to 9000. Got a 2nd diagnostic (Jeff wyler hyundai cincinnati) Completely different result- Zero mention of motor ' said Ac compasitor failed. (Had no issues prior to them working on the original recall ) The light for the recall is still on by the way and they want me to pay 3500 for new AC capacitor . (600 diagnostic included in that price ) " The dealership’s failure to properly perform the inverter coolant refill recall directly caused the AC compressor failure in my 2021 Hyundai Kona EV. Before taking the vehicle in for the recall, the AC system was fully functional, delivering cold air without any issues, and the car experienced no charging problems, indicating the battery and cooling systems were operating normally. The recall, intended to flush the inverter cooling system and replace the crystallizing BSC-1 coolant with BSC-2, was not completed correctly, as evidenced by the dealership’s admission that they couldn’t fix it. This botched service likely left air or debris in the cooling system, which, in Kona EVs with a heat pump, could overwork the AC compressor used for battery cooling during charging. The compressor’s failure shortly after the recall service, despite no prior issues, strongly suggests that the improper coolant flush caused undue stress on the compressor, leading to its $3,000 failure, which should be covered under warranty or as a goodwill repair due to the dealership’s error". [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Incident: May 31, 2025 · Filed: June 26, 2025

The car was unable to charge using level 3 DC fast chargers, necessitating the use of a level 2 charger for an extended length of time in order to be able to return home. A Hyundai dealer replaced the charging inlet lock actuator (invoice attached).

Incident: August 16, 2024 · Filed: June 25, 2025

After powering on the car, the dashboard displayed multiple brake system warnings, including the brake system warning light and a message on the LCD display that read "Check regenerative brakes." A Hyundai dealer replaced the integrated electric brake unit assembly (invoice attached).

Incident: September 1, 2024 · Filed: June 6, 2025

My wife's car t-boned another vehicle, but the air bags didn't deploy. Luckily, she wasn't hurt badly, but the vehicle was deemed a total loss, so you can imagine the force of the collision. The forward collision warning and automatic emergency braking didn't activate either. I reported it to Hyundai. They sent an inspector to examine the vehicle, and I also showed them photos and a copy of the police report, but they claim that my car was hit on the side, and the pre collision system doesn't detect imminent side impact. That's completely outrageous. I don't know what their inspector wrote in their report, but the photos and police report are irrefutable proof that my wife had a frontal collision with the side of another vehicle. Hyundai kept denying it because they didn't want to help financially. I attached a copy of their determination letters (the second one was after I submitted a copy of the police report to prove that my wife's car is the one that hit the other vehicle, but Hyundai refused to see it as it happened). This is a link to see the interior and exterior photos of the vehicle: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Incident: April 28, 2025 · Filed: April 28, 2025

Fill coolant warning came on, we checked the coolant and the coolant level was good. I spoke to a Hyundai service center and the rep said that sometimes this happens with Hyundais and it may go off. Indeed it did but then Fill coolant warning came back and the coolant level was still good. After several weeks of the Fill Coolant warning being on more often than not, the car started one morning but couldn’t be driven as the handbrake was stuck on, the fill coolant warning was on and the tire pressure warning was on, (even though the tire pressure on all tires was ok) I guess this was the EVs way of saying “Do Not Drive Me”. We got the car to the dealership, they performed a scan and found no codes. They preformed a total coolant flush as per Service Campaign T9E. This service was performed on 21 April, 2025 and thus far the fill coolant light has stated off. We bought this car used just 2 months prior and found through previous maintenance history that this EV had this service Campaign T9E done in January 2024. Our concern with this issue is two fold, 1) My wife could have been anywhere when the car went into: Don’t drive me mode. 2) is this going to be an annual event, which will cost several hundred dollars to address each time when this may no longer be covered by warranty