2023 Hyundai Santa FE Hybrid Recalls & Complaints

Incident: October 8, 2026 · Filed: October 10, 2026

The vehicle came to a complete stop filling cabin with smoke and wouldnt start in a bend on road blocking entrance ramp. Its available for inspection but at dealership. My safety was put at risk for collision as well as health with cabin filling with smoke. The dealer still has vehicle going on 3rd day without answers. The vehicle had warning come on for hybrid system failure appearing shortly before dying completely with smoke filling cabin.

Incident: March 26, 2026 · Filed: June 3, 2026

I am submitting this formal safety complaint regarding a structural defect in my 2023 Hyundai Santa Fe Hybrid that I believe poses a safety concern and warrants federal investigation under the National Traffic and Motor Vehicle Safety Act (49 U.S.C. § 30101 et seq.). The vehicle exhibits a persistent and recurring structural creak originating from the pinch weld area adjacent to the hybrid battery storage compartment — specifically at a metal-on-metal contact point above the rear driver-side wheel well. The noise presents most prominently at low speeds over uneven surfaces, driveway transitions, and speed bumps. The root cause, as identified by service documentation and owner community reports, is a manufacturing defect in the pinch weld construction where two metal body components make contact due to insufficient clearance tolerances. This affects the structural integrity of the body-in-white in proximity to the hybrid high-voltage battery system. III. SAFETY SIGNIFICANCE I am reporting this as a safety concern for the following reasons: •The defect involves structural body components adjacent to the high-voltage hybrid battery storage compartment. Any degradation of body structure in this area presents a potential risk of battery exposure, puncture, or damage in collision scenarios; •The metal-on-metal contact at the pinch weld constitutes an ongoing structural stress point that may accelerate fatigue and cracking of load-bearing body components over time; •The defect is present across a statistically significant number of 2023 Santa Fe Hybrid units based on online owner community documentation, suggesting a manufacturing pattern rather than an isolated anomaly; •Multiple authorized Hyundai service centers have been unable to provide a permanent repair, indicating the defect is systemic and not addressable through routine service procedures; •The proximity of the defect to hybrid drivetrain components warrants evaluation for potential regulatory compliance

Incident: February 20, 2026 · Filed: February 22, 2026

Own a 2023 Hyundai Santa Fe Hybrid and have experienced the following issues over the past year and a half. Beginning after maybe 40,000 miles we pulled out onto a roadway and the engine immediately lost power and started flashing a glaring red warning that the hybrid system was failing and to pull over. We luckily were able to and turned the car off and waited. I tried to turn it on and it came back to life as if there was never an issue? We drove off. it left no warning code or did not update my Bluelink App. I took it to the dealership and they could not find any issues. Fast forward another 5 or 6 months and it happens again. Take it to the dealer and they keep it a week to go over it but still nothing. Within a week of getting it back it happens again and this time I am videoing it happening to me. Back to the dealer and provide the video because again the car did not log the event nor did it update my app. They hold it again for a week and try different things. They still cannot figure it out and I get it back.... it happens again.... This time the dealership was able to come up with an answer and that the oil level was too high. I got the car back and it seemed to work. Probably now 6 months go by and then this week I drive over to Jacksonville (5 hr drive) and visit. Again the car scares us on the highway and I have to pull over. Havea friend meet us with tools and we jack up the car and let out enough engine oil to insure we can read between the two marks on the dipstick. We drive off but the engine keeps hestitating and we almost make it back before it completly shuts down. We tow it to the Dealer in Jacksonville. They call the next morning like they can't find anything wrong! I explain everything and remind I don't tow cars for fun - something is wrong with the car and it is leaving us vulnerable and worst is it is not leaving any codes. Not sure but I have lost faith in Hyundai

Incident: November 11, 2025 · Filed: December 21, 2025

One two separate occasions while driving the car has lost the ability to accelerate. There is no acceleration power even when completely flooring the gas pedal. The dash displays a red circle warming that states "Check Hybrid system. Stop Safely". I have had to coast to the side of the road and then the car shuts off. It has taken several minutes before it can start again, and then displays a warning "Park with engine On to charge battery" before being able to shift the car into drive. I immediately took the vehicle to the dealership at which I had purchased the car. They have run a diagnostic on it and did not find any error codes stored in the computer. I picked up the vehicle from them and immediately upon pulling out of their lot it happened again. After losing power, coasting to the side of the road, and waiting for the engine to be able to restart I took it immediately back to the dealership. They have had my car for 5 weeks and cannot diagnose the problem or offer any recommendations for repairs.

Incident: December 6, 2025 · Filed: December 14, 2025

The vehicle will not accelerate and comes to a complete stop while driving. Within days, it displayed ‘Check Hybrid System. Stop safely’ and lost propulsion while driving.

Incident: September 4, 2025 · Filed: September 25, 2025

On September 4, 2025 as I pulled on to Interstate I-70 my car suddenly lost power. Gas engine died. Loud attention sound started. Instrument cluster started flashing red with message "EV system failure, stop immediately" EV battery showed full depletion although a moment before it showed about 75% power. There was only enough propulsion to keep moving slowly. Since this was a construction zone the shoulder was blocked off and roadway was reduced to only one lane. I had no where to go. A large truck narrowly avoided rear ending me. I was scared and felt helpless. Eventually I was able to pull off and shut off the car. It was able to be re-started immediately with no warning indicators and EV battery power restored. This loss of power has happened 6 times before during the time I have owned the car. Last time was in March 2025. Each previous time it happened I was traveling at about 35 miles per hour and while annoying I did not fear for my life. On March 6, 2025 I had the dealer, McCarthy Hyundai, check out this problem. There were no detectable problems or problem codes. I was told that it might have been caused by the oil dip stick not being fully seated. It was obvious they had no clue what caused this but that I should come back if it happened again. I have reported this to Hyundai customer service who would not confirm that this was a problem encountered by many others. From looking at reports on the internet, my problem is not unique except for being life thretening. Customer service had me bring it back to dealer. Yesterday, September 24, I picked up the vehicle whohad it for a week to try to fix the problem. Once again there were no error codes. Only problem they found was an ignition coil which needed to be replaced. They could not give a convincing explaination of how a bad ignition coil could cause a complete failure of the gas motor and EV system or why if the coil was sole problem that it would only cause this failure every 3 to 6 months. Please help!

Incident: July 16, 2025 · Filed: July 22, 2025

I am reporting a serious and recurring safety defect with my 2023 Hyundai Santa Fe Hybrid, purchased new in January 2024. The vehicle has suffered from over 30–40 sudden hybrid system failures, including loss of acceleration, “Stop Vehicle” warnings, and check engine lights. These incidents happen without warning, including while driving at legal speeds (40–70 mph), on residential streets and highways. Most recently, the car failed twice in two days, while my teenage son was driving within all road laws, including once with a friend in the car. The vehicle simply stopped accelerating in the middle of traffic, endangering them and everyone around them. These failures have happened at legal speeds ranging from 40–70 mph, on both residential roads and highways. There is no advance warning, just abrupt loss of power and sudden warning messages. We’ve taken the vehicle to the South Charlotte Hyundai dealership multiple times. Each time, they either reset the check engine light or replaced indicators: but never addressed the root hybrid system failure. We filed a lemon law case, and Hyundai responded with only a $2,000 offer including legal fees, requiring us to keep the dangerous vehicle. We rejected the offer. These failures have occurred with children and passengers in the car. We have documented as many incidents as we could, including photos, service records, and communication with Hyundai. The vehicle is available for inspection upon request. I no longer feel safe driving or allowing my family to drive this car. This is a critical hybrid system failure that continues to place lives at risk. I believe this may be part of a wider pattern affecting Hyundai hybrid vehicles, and I am pleading with the NHTSA to open an investigation before someone is seriously injured or worse.

Incident: July 6, 2025 · Filed: July 6, 2025

We were driving in Montana down [XXX] and heard a very large “pop” sound above us. Our vehicle was traveling alone in the area at the time, no other vehicles were around ours. There was no debris on the road or flying in air at the time, either. At this point the panoramic roof glass was closed but the interior cloth cover was open and there was no evidence of any damage. When we stopped for gas, the front glass panel covering behind the windshield and before the panoramic roof glass, was completely shattered. The weather was the same as it had been, 80F with minimal cloud coverage. There was no sudden change in weather/driving conditions.

Incident: January 31, 2025 · Filed: June 23, 2025

Between [XXX] am on [XXX]. I powered on my vehicle and the rear trunk door simultaneously opened. As I was driving my son to school that morning, I noticed water dripping onto my foot. I continued to drive but was distracted by beeping and warning messages but because the dashboard display was constantly switching from daytime to night lighting I could not readily see the dashboard. I tried to manually adjust the light by turning the knob off "auto" and also turning lights to "off" but it would immediately switch back. I made it to the first stop light and while stopped I was able to observe water droplets on the front panel of the interior fuse box. I pulled open the panel and water dropped out onto to floor. I replaced the panel. I continued to drive but was panicked and worried that water was in the fuse panel area. I arrived at my son's school and left the car running as he was dropped off. On the drive home, the beeping continued. This time, I saw the warning message about vehicle in my blind spot but I was on the street corner about to make a right turn and there was no vehicle next to me! The lights also kept switching as before. There was rust observed in the fuse panel area. When I got home, I called the dealership to inform them what happened. They refused to give me a loaner. I told them that water intrusion should not have occurred (we had severe weather and heavy rains the day prior) and now my car was having electrical issues and I was concerned for my safety and the safety of driving my 3 young children in car seats should there be an electrical fire. I mentioned the recall on my vehicle for water accumulation in the tow hitch and risk of electrical fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Incident: May 11, 2025 · Filed: May 21, 2025

I am reporting an URGENT REQUEST IMMEDIATE ACTION REGARDING A SERIOUS UNRESOLVED, RECURRING PUBLIC SAFETY ISSUE WITH MY VEHICLE. IT IS POTENTIALLY THE FAULT OF ALEXANDRIA HYUNDAI'S SERVICE DEPARTMENT (in Alexandria, VA) WHO HAD JUST SERVICED MY VEHICLE FOR WHAT SHOULD HAVE BEEN A ROUTINE SERVICING (on May 7). My car had a catastrophic and complete failure on a high speed highway (the car quickly decelerated) which represented an incredibly danger situation for myself and other drivers on the road. My car was purchased in 2023 and has 15,241 miles. It has been perfectly maintained. On [XXX], I was returning to my home in Virginia from Maryland on an 8 lane highway with a 55mph speed limit when I had a very dangerous complete failure of my car. Simultaneously, the car started bucking back, the speed was decelerating regardless of my pressing the accelerator to keep my speed the same as traffic, and I received a flashing large red message that said "CHECK HYBRID SYSTEM - STOP SAFELY." Fortunately I was in the far right lane and was able to veer it over to a narrow shoulder. It was 8pm and getting dark. After a short while, the car lost all power so I was on a narrow shoulder with no lights flashing anymore. I was in this dark car with a lot of traffic speeding my with my 2 dogs. I became incredibly stressed about how we were going to get home. I contacted AAA, a police officer and Uber Pet who worked together in this unsafe situation on the side of the highway to get myself and my dogs home into the Uber vehicle with only the front door opening (no power). It was over 2 hours before I was home safely It was incredibly stressful situation. The car was towed to Alexandria Hyundai and they dismissed the issue and fixed nothing. I contacted Hyundai customer service and asked for escalation and they have done nothing. I am restricted in my driving because of the severe safety risk but had to drive again on [XXX] and it occurred again on a highway INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)