2015 Hyundai Sonata
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Vehicles › Hyundai › Sonata › 2015
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
These records cover every 2015 Hyundai Sonata. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
9 recalls name the 2015 Hyundai Sonata. Newest first.
Hyundai Motor America (Hyundai) is recalling certain 2015-2017 Sonata, 2016-2017 Sonata Hybrid, and Sonata Plug-In Hybrid vehicles. The Smart Junction Box (SJB) software logic may not properly interpret the signals received from the multifunction switch, which could cause the turn signal to activate in the opposite direction of what the driver intended.
A turn signal that activates in the opposite direction of what was intended by the driver increases the risk of a crash.
Dealers will update the SJB software, free of charge. Owner notification letters were mailed November 19, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 210.
Hyundai Motor America (Hyundai) is recalling certain 2015-2016 Sonata and Genesis vehicles. In the affected vehicles, the warning light to indicate that the parking brake is applied may intermittently not illuminate in the dash due to corrosion in the switch.
If the parking brake indicator is not illuminated when the parking brake is applied, the driver may operate the vehicle with the parking brake partially engaged, increasing the risk of a crash.
Hyundai will notify owners, and dealers will replace the parking brake switch, free of charge. The recall began on August 4, 2017. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 164.
Hyundai Motor America (Hyundai) is recalling certain model year 2015-2016 Sonata Hybrid vehicles manufactured December 8, 2014, to August 18, 2015, and Hyundai Sonata vehicles manufactured May 28, 2014, to March 18, 2016, equipped with the panoramic sunroof option. Due to a bonding issue with the sunroof wind deflector, the sunroof panel on the affected…
If the sunroof detaches from the vehicle it could become a road hazard, increasing the risk of a crash.
Hyundai will notify owners, and dealers will repair the wind deflector anchor plate, free of charge. The recall began December 2016. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 152.
Hyundai Motor Company (Hyundai) is recalling certain model year 2015-2016 Sonata vehicles manufactured May 29, 2014 to February 11, 2016, 2017 Elantra vehicles manufactured January 12, 2016 to February 22, 2016, and one 2016 Sonata Hybrid vehicle manufactured October 15, 2015. In these vehicles, the driver's frontal air bag may be missing a chemical…
An air bag that does not inflate increases the risk of injury.
Hyundai will notify owners, and dealers will replace the driver's frontal air bag module, free of charge. The recall began on May 5,2016. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 144.
Hyundai Motor America (Hyundai) is recalling certain model year 2015-2016 Sonata vehicles manufactured May 28, 2014, to August 21, 2015. The affected vehicles are equipped with an Antilock Braking System (ABS) warning light intended to warn the driver if there is an ABS malfunction. In the event of an ABS malfunction, the Brake System warning light will…
If the driver is alerted there is a brake system malfunction, but not specifically with the ABS system, the driver may operate the vehicle unaware that the vehicle's brakes may lock up during hard braking, increasing the risk of a crash.
Hyundai will notify owners, and dealers will update the ABS control unit software, free of charge. The recall is expected began on November 30, 2015. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 134.
Hyundai Motor America (Hyundai) is recalling certain model year 2015 Sonata vehicles manufactured April 25, 2014, to December 4, 2014. The affected vehicles have a front passenger seat belt whose buckle latch assembly may prevent the front passenger from fastening the seat belt.
If the front passenger seat belt cannot be latched, an occupant sitting in the front passenger seat has an increased risk of injury in the event of a crash.
Hyundai will notify owners, and dealers will repair or replace the front passenger seat belt buckle, free of charge. The recall began on September 15, 2015. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 130.
Hyundai Motor America (Hyundai) is recalling certain 1.6 liter model year 2015 Sonata vehicles manufactured August 29, 2014, to October 28, 2014. The affected vehicles may have been assembled with an incorrect left axle shaft which may result in the shaft separating from the transaxle differential.
If the left axle shaft separates from the transaxle, the vehicle may stop moving, increasing the risk of a crash. Additionally, a separated axle shaft may allow the vehicle to roll away as the driver and other occupants exit the vehicle or anytime thereafter. A vehicle rollaway increases the risk of injury to exiting occupants and bystanders.
Hyundai will notify owners, dealers will inspect and replace the axle shaft, as necessary, free of charge. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 126.
Hyundai Motor Company (Hyundai) is recalling certain model year 2015 Sonata vehicles manufactured April 25, 2014, through June 16, 2014. Due to a manufacturing error, one or both of the front brake calipers may fracture.
If a brake caliper fractures, brake effectiveness would be reduced, lengthening to distance required to stop the vehicle, increasing the risk of a crash.
Hyundai contacted the affected owners on June 19, 2014 and instructed them not to drive their vehicles. Hyundai dealers will replace the affected brake calipers, free of charge. The recall began on September 12, 2014. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 120.
Hyundai Motor Company (Hyundai) is recalling certain model year 2015 Sonata vehicles manufactured May 2, 2014, through May 23, 2014. A poor connection within the vehicle's wiring harness may result in a reduction of steering assist from the vehicle's motor driven power steering system or the inability to move the vehicle's shifter from the Park position.
The reduction of power steering assist can increase the steering effort needed, increasing the risk of a crash.
Hyundai notified dealers to suspend sales of affected Sonata vehicles and has published recall bulletin 14-01-024 providing a service procedure to repair the affected vehicles. On June 7, 2014 Hyundai began to contact the affected retail customers. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 119.
On Wednesday, October 21, 2026, our 2015 Hyundai Sonata with the 2.4L Theta II GDI engine suffered a sudden, complete engine seizure while traveling about 75 mph on I-25 Southbound near Castle Rock, CO. A family member was driving. Warning lights across the car began flashing, the engine made a loud grinding noise, and the brakes stopped working. Over a long distance, the driver was able to get the car onto the shoulder and bring it to a stop, then engage the parking brake. There was no collision and no injuries, only because traffic was light. The car was towed to a repair shop, then transferred to a second shop, which determined the engine had seized and requires full replacement. This vehicle is covered by Hyundai's Theta II GDI engine campaigns for connecting rod bearing failure. On October 26, 2026, Hyundai told us the Knock Sensor Detection System software update (Campaign 953) was never completed on this vehicle and declined coverage. Neither we nor the prior owners, who are family members, recall receiving any notice of this campaign. All previous check engine lights were diagnosed and repaired at independent shops, including an intake manifold replacement in April 2024, and no shop ever identified an open engine campaign. A full engine seizure at highway speed, combined with the loss of braking, creates a serious crash risk for the driver and surrounding traffic.
A franchise dealership performed a federally mandated safety recall service (ECM Software Update) and a knock sensor replacement on this 2015 Hyundai Sonata 2.0L Turbo. To perform these specific repairs, the technician had to work directly around the intake and turbocharger assembly workspace. Immediately after picking up the vehicle, it suffered a sudden and dangerous loss of power and refused to accelerate normally on the highway, creating a severe traffic hazard. Upon an immediate emergency inspection by the same service center 5 days later, the dealership documented in writing that the turbocharger intercooler hose clamps were completely off/unfastened. Because the technician left the clamps disconnected, the turbo lost sealed pressure, failed completely, and began dumping high-pressure engine oil backward through the air filter intake box. The service center is now refusing to take responsibility for the mechanical safety failure directly caused by their technician's recall repair negligence.
The contact owns a 2015 Hyundai Sonata. The contact stated that while driving at 20 MPH, the driver-side windshield wiper failed to function properly. The vehicle was taken to an independent mechanic, who determined that the wiper blade was not making proper contact with the windshield due to a bent driver-side windshield wiper arm. The dealer was contacted and confirmed that no recall coverage applied to the failure. The contact associated the failure with NHTSA Campaign Number: 23V180000 (Visibility/Wiper). The contact notified the Hyundai manufacturer of the issue by phone. The failure mileage was approximately 26,400.
Hyundai Motor America is explicitly refusing to honor the mandatory safety recall and lifetime warranty extension for a catastrophic rod bearing failure on my 2015 Hyundai Sonata (VIN [XXX]). The engine suffered a sudden internal connecting rod bearing seizure while operating, causing a complete loss of motive power and creating an immediate hazard. Hyundai Corporate Escalations issued a blanket denial solely because the vehicle carries a rebuilt title. However, the vehicle's official Hyundai portal confirms that Service Campaign 953 (the Knock Sensor Detection System software update) was successfully completed on XXX. The engine failure matches the exact factory manufacturing defect (internal oil starvation from manufacturing debris) that is the subject of the In re: Hyundai and Kia Engine Litigation. The external collision history that led to a structural/rebuilt brand has absolutely zero mechanical correlation to a sealed, internal crankshaft block defect. Hyundai is acting in bad faith by using an unrelated title status to evade a federal safety recall mandate and escape liability for a dangerous, stalling powertrain defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
I received a notice from Hyundai that there was a Service Campaign 9C2 for my car. My car was running fine but I took it to Jones Hyundai in Belair MD for oil change and the Service Campaign. After this work was done my car lost driveability, poor throttle response and transmission searching for correct gear. I notified Hyundai about my concerns and they replied they opened a case number. Corporate advice so far has been to let the car warm before driving, which has been marginaly helpful. It is hard to merge with high speed traffic because of poor throttle response and transmission searching for correct gear, I have had some close calls. I think cold weather will increase this problem.
I am filing this complaint regarding transmission and drivability problems with my 2015 Hyundai Sonata 2.4L following Hyundai Campaign 9C-2. My vehicle was running and driving perfectly before this update. I have always maintained it on time, followed proper maintenance schedules, and have records documenting its maintenance history. I never experienced these transmission issues before the update. The problems began immediately after the campaign was performed. In fact, I noticed the abnormal shifting before I even left the dealership after picking up my vehicle. Since the update, the vehicle has experienced poor and abnormal shifting behavior. I contacted the dealership to report the problem and also filed a complaint directly with Hyundai Corporate. I was told that Hyundai is aware of the issue, yet my complaint remains unresolved. I also located a document online indicating that Hyundai is aware of this problem. Additionally, I have seen numerous reports from other Hyundai owners describing similar transmission problems after receiving this same update. My vehicle has approximately 82,000 miles. The engine was replaced approximately one year before this complaint. Given the vehicle's excellent operation before the update, my documented maintenance history, and the immediate onset of the problems at the dealership, I am seriously concerned that Campaign 9C-2 caused or contributed to these transmission issues. I am requesting that NHTSA investigate whether this software update causes or worsens transmission shifting problems in affected Hyundai vehicles. Hyundai's awareness of the reported issue and the apparent number of similar owner complaints make this especially concerning. I believe this issue deserves investigation to determine its cause, assess any potential safety risks, and establish whether corrective action
Ever since the 9C2 software update was completed on 94/26, the car is experiencing hesitations not only in the first few minutes of driving but after the engine is hot. It was driving perfectly before this update.
On May 28, 2026, the panoramic sunroof on my 2015 Hyundai Sonata became off track while I was driving. I could not get the sunroof back into its proper position because it was off track. I continued driving, and while I was traveling on the highway, the sunroof panel detached from the vehicle and flew down the highway. This created a serious safety hazard to me and other motorists. I was not the original owner and did not know the vehicle was subject to a recall. After the incident, I researched the vehicle and discovered Hyundai's Sonata Panoramic Sunroof Recall, Campaign 152. Hyundai's official website states that my vehicle is affected by the recall. Hyundai's recall description states that the wind deflector can interfere with the movable sunroof panel and, in some cases, cause the panel to detach from its mounting tabs. It specifically warns that if the panel detaches while the vehicle is in motion, it could become an obstacle to other drivers and increase the risk of a crash. This is what happened to me. After discovering the recall, I took the vehicle to a Hyundai dealership to have the recall addressed, but the dealership refused to perform the recall repair. Hyundai's website states that the dealer will repair the wind deflector anchor plate at no charge. I'm asking NHTSA to determine the appropriate remedy when the recalled condition actually occured and resulted in the sunroof panel detaching while the vehicle was in motion.
am seeking assistance regarding a sudden and unexpected engine failure with my vehicle. The Sonata only had approximately 80,000 miles on it when the engine failed. Prior to this happening, I had never experienced any problems with the vehicle. There were no warning lights or other indications that there was an issue with the engine, and the vehicle had passed inspection. The engine failure happened completely out of the blue. I have also kept up with the vehicle’s maintenance, including regular oil changes. I recently replaced the battery and tires as well. Hyundai previously denied my claim, stating that the vehicle’s salvage title was the reason for the denial. However, I would like the circumstances of the engine failure and my maintenance history to be fully considered. The vehicle had relatively low mileage, was maintained, passed inspection, and showed no warning signs before the engine suddenly failed. I can provide maintenance records, receipts, inspection records, photographs, repair records, and any other documentation needed to support my claim.
"I am filing a complaint regarding severe vehicle jerking, engine surging, and rough transmission shifting immediately following the completion of Hyundai Service Campaign 9C2 (TSB 26-01-013H-1) on my 2015 Hyundai Sonata. The vehicle exhibits dangerous hesitation and lurching during cold starts. This behavior creates a traffic hazard when pulling out of driveways or into intersections during the first 3 minutes of operation. The manufacturer has acknowledged this cold-start defect in an internal 'Drivability Information' memo but has not provided a permanent remedy to repair the software logic."
After receiving the Hyundai Service Campaign 9C2 update on my 2015 Hyundai Sonata on XXX, I have started having jerky acceleration when the car is first started and am driving. Also, while driving at highway speed (~65 mph)) and I take my foot off the accelerator to coast, the engine RPM drops suddenly, anywhere from 250 rpm to 750 rpm, then recovers abruptly to where it was at prior to the drop (typically around 2000 rpm). The engine rpm also drops while driving at slower speeds and recovers but is not as noticeable as it is at highway speeds. It was not doing this prior to the Service Campaign. There are no check engine lights or pending codes. I brought it back to the Hyundai dealer and discussed the issue with them on XXX. They acknowledged it was likely due to the Service Campaign and they did not want to keep the car to look at it and said no damage was being done and it was safe to drive. They said a fix was in the works but did not know how long until it was released and I should receive information in the mail on it. Video link [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
In March 2026 Hyundai did an emissions update Campaign 9C2. Since that update my 2015 Hyundai Sonata SE has run rough and shifted hard. Hyundai stopped doing the update in May 2026. Hyundai has not provided any update to fix the problem they created. I am worried the update is damaging the motor and transmission of a car that was running just fine prior to the update.
The engine failed due to the known recall defect, dealer confirmed loss of compression in cylinders 2 & 4. I am a federal employee stationed overseas on official duty orders, and Hyundai Motor America is delaying safety recall remedies and buyback negotiations since June 9th.
Engine locked up, crank bearing failure, found out there is known failures with this problem and Hyundai had a class action suit against them in the past and issued lifetime warranty for this engine due to this problem. Took car to local dealer, Clay Cooley in Sherman TX, they have been great but Hyundai corporate has denied the claim stating lack of maintenance records. Car has 175,000 miles on it, I have only owned it for about 5-6,000 miles. I have changed the oil in it twice myself I was able to prove one of those with a receipt but I don't have the other receipt and have been unable to get it. The dealer has records of oil changes up to 150k miles then I was able to find additional proof of other oil changes through car fax at smaller lube shops. The previous owner before me changed their own oil also and did not keep receipts I reached out to them with no luck. Ultimately there is only about a 10k mile gap of unprovable maintenance, this engine model has a known issue, it did not make it to 175k miles without proper maintenance, I can't control what previous owners did with their receipts but lifetime warranty should be lifetime not only if you can prove every detail from people you can't control.
I bought this car new in 2015, when I was at 97000 miles they had to replace the motor and turbo, I am now at 155844 and they are telling me that basically all 4 cylinders have low compression, cylinder 3 is the worst. They are telling me that this car has to have a new motor. I have not done anything to this vehicle to cause no compression. They want me to pay around 8800.00 to get this fixed.
Issue- fuel pump/supply line causing fuel to leak and fuel smell around the outside of the car. This can cause a major fire, explosion, death for myself and others around me. Problem has been confirmed by auto repair shop. No warning messages on car dash board, just strong smell of gas. Replaced gas cap and smell is still there.
Brake lights not working properly.
My Hyundai Sonata engine stalled out while driving on the highway. I had it towed to a dealership with the hope they would fix the issue because it was supposed to be covered under warranty from a recall. The dealership said the engine replacement would be covered as long as they got approval from Hyundai. Hyundai apparently only asked that specific dealership for the service records that they had, didn’t even reach out to me or try to find any other service records on the vehicle and denied the claim for “neglect of maintenance” because that dealership only had records from 0-90,000 miles. The dealership got back to me and told me the news and I told them that I will get all service records from 0 miles to current. I got all those records together and sent them to the dealer. A week later they called and said Hyundai was again going to deny my request because of the same “neglect of maintenance” which isn’t true based on the records I have and they have. I have driven the vehicle less than 10,000 miles and there has been nothing wrong with it. No check engine lights ever and regular oil changes.
The contact owns a 2015 Hyundai Sonata. The contact stated that while driving on several occasions at various speeds, the vehicle lost power, and the check engine warning light was illuminated. The vehicle was taken to a dealer where it was diagnosed that the engine had failed and needed to be replaced. The vehicle was repaired, but the failure reoccurred within a year. The vehicle was taken back to the same dealer where it was diagnosed and determined that a software update was needed. The vehicle was repaired, but the failure persisted. The vehicle was then taken back to the same dealer, and there was oil on the pistons and a tune-up was needed. The vehicle was repaired, but the failure persisted. The vehicle was taken back to the dealer, where it was advised that an oil consumption test could not be provided until the pistons had failed. The manufacturer was notified of the failure, and a complaint was filed. The failure mileage was approximately 88,000.
Vehicle: 2015 Hyundai Sonata VIN: [XXX] Mileage: ~85,000 Description of the Problem: While driving, the vehicle suddenly began producing thick smoke from under the hood without warning. I safely maneuvered to the shoulder to avoid an accident. The engine subsequently seized completely and became inoperable. My mechanic diagnosed this as a known internal manufacturing defect in the Theta II engine (connecting rod bearing failure), a widely documented issue for this model and production year. Oil and coolant levels were confirmed normal with no leaks, ruling out maintenance neglect. I initially paid for an unnecessary starter replacement before this diagnosis was confirmed. This is a serious safety hazard that could cause loss of engine power and control while driving, posing a risk to myself and other drivers on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
1.) Following Hyundai's 9C2 Campaign update for the ECU that was completed back on May 27th, 2026, my 2015 Sonata went into limp mode [solid check engine light present] while I was accelerating up an on-ramp on the 2nd drive cycle since the update was performed. I was already far away from the dealership so I was forced to limp it to my local shop that I regularly use to have it checked out. It was confirmed that the code on the vehicle was P200A for intake manifold runners. Since the update was for smog regulation, the code was cleared in order to see if it would come back. Since then, it has not, however the vehicle continues to have one persistent problem. The RPMs will dramatically dip and then surge back upwards while the car is coasting (no gas and no brake applied). 70% of the time, you can feel the car violently jerk as it appears to try and correct itself. 2.) I've brought this car to multiple dealerships, have a case open with corporate and have also found that this is a systemic issue with this specific update in these cars. All and all, nothing has been done. I'm repeatedly turned away over and over again because their techs are only permitted to look into it once they have hard evidence of a fault. In this case, that would be a dashboard light. I'm told that I may only return if the check engine light comes back, which as I mentioned previously, posed a HUGE safety risk to myself the first time it appeared. If I can only go 55mph down the highway, I am at risk of being rear-ended or struck in some way. 3.) The problem has not been reproduced by the dealer as they will not test drive it to see the dip and spike. However, the code was still pending for awhile in the vehicle before it cleared it on its own, so that was acknowledged by at least one place. 4.) Vehicle has not been inspected by anyone but a dealership and local mechanic. 5.) No other signs prior to the vehicle limping out on me other than some acceleration concerns on May 27th, 2026.
Since the 9C2 update on June 24, 2026, my vehicle has not driven the same. I'm experiencing clunky or harsh gear changes at low speeds, especially during stop-and-go driving. When I slow down and then accelerate again, the vehicle sputters or hesitates before responding. While driving at lower speeds, I also feel intermittent skips or small surges, almost like bubbles or brief misfires. These symptoms were not present before the 9C2 update, and they have noticeably affected the drivability of the vehicle. It was suggested the transmission needed time to "relearn" driving patterns, but it has been several weeks with no change
Engine / Short block assembly / Connecting rod bearing seizure. The engine suffered a sudden, catastrophic seizure while I was actively driving on a steep incline mountain road with a cliff on one side and forest on other. The vehicle experienced an immediate, total loss of motive power, forcing an emergency maneuver onto the shoulder in 5 seconds with no power steering or power brakes, creating an extreme collision hazard on a high-speed incline. The rod bearing melted due to a manufacture defect and could have also possible caught fire in heavy fire country. The fuel pump was also leaking recently and just replaced. They are nearly $1800 for a new pump because of price gauging because they are in "high demand". The Check Engine Light was solid (not flashing) for a thermostat code (P0128) due to extreme internal friction/heat from the failing bearings. There were no flashing KSDS warnings or physical signs of engine overheating. My car was denied a new engine under a Federally Mandated Warranty explicitly stating the exact symptoms of internal engine defect that happened in my car under "owner neglect" even though I have changed my oil regularly and even before the manufacture recommended time frames to do so. I've changed the valve covers, 02 sensors, thermostats, and plenty more on this car than any other car I have ever owned proving I'm actually an exceptional owner. I remained nice to all corporate staff during this process while they denied my car proper care under a Federal Mandate. I bought this car to believe that Hyundai was a superior company in regards to warranties, price, and function as opposed to the more expensive counterparts of the same class. Which in the end has cost me way more, and almost my life. This car is dangerous and the company has done everything in their power to try to cover it up while placing blame on the very consumers that are believing in them to do better.
Driving vehicle at slow speed crossing an intersection and engine completely shut down. The engine has completely seized and needs replaced due to a known recall. I have only owned the vehicle for 7 months. Hyundai is refusing to pay for engine replacement claiming a previous recall prior to me owning the vehicle should have been completed. I only drove the vehicle 1,000 miles in that time at nothing over 50 mph. There was no notification to me about this recall.
I was driving my 2015 Hyundai Sonata approximately 35 mph after leaving the Hyundai dealership following an engine replacement when the hood unexpectedly flew completely open without warning. The hood struck the windshield, completely obstructing my forward visibility and creating an extremely dangerous situation. I was able to safely pull over without causing a collision, but the vehicle sustained extensive damage and was declared a total loss by my insurance company. During the same service visit in which the engine was replaced, the dealership recommended replacing the hood latches, but I declined that repair. Hyundai later informed me that the hood latching system was functioning properly after the engine replacement and that the vehicle passed its post-repair inspection and road test. Approximately one mile after leaving the dealership following the engine replacement, the hood unexpectedly opened while I was driving. There were no hood-ajar warnings, warning lights, or other indications that the hood was not properly secured before the incident. The sudden loss of visibility created a serious risk of a crash that could have resulted in severe injury or death. I am submitting this complaint because I believe this incident represents a significant vehicle safety issue that should be investigated.
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
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.
On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles. During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types. The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement. Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia. The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio. The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires. In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines. The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS. It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension. For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied. Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates. To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years. In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires. Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis. Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023). The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW. The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications. The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU. In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment. FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle. Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW. These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes. An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time. In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU. This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners. Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW. The risk associated with the ASIC is equally shared among all OEMS involved in the investigation. The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage. There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation. The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU. If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC. Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC. All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled. In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024. With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.