2021 Hyundai Sonata
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Hyundai › Sonata › 2021
These records cover every 2021 Hyundai Sonata. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
4 recalls name the 2021 Hyundai Sonata. Newest first.
Hyundai Motor America (Hyundai) is recalling certain 2020-2023 Sonata vehicles. A damaged check valve can allow air to enter the fuel tank, causing it to expand and contact hot exhaust components, melting the tank.
Risk and remedy
Risk
A melted fuel tank can leak, increasing the risk of a fire.
Remedy
Dealers will inspect and replace the check valve. The fuel tank assembly will be inspected for damage and replaced if necessary. Additionally, dealers will inspect and update the engine control unit software. All repairs will be performed as necessary, free of charge. Owner notification letters were mailed beginning March 13, 2026. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 286. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on November 19, 2025.
Hyundai Motor Company (Hyundai) is recalling certain 2021-2022 Santa Fe, Sonata, Veloster N, 2022 Santa Cruz, Elantra N, and Kona N vehicles. The vehicle's "fail-safe" limited-mobility drive mode may be impaired, when prompted by a transmission oil pump malfunction, which can result in a complete loss of drive power.
Risk and remedy
Risk
Loss of drive power increases the risk of a crash.
Remedy
Dealers will inspect and replace the transmission, as necessary. Dealers will also update the transmission control unit software. All repairs will be performed free of charge. Owner notification letters were mailed January 10, 2023. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 236.
Hyundai Motor America (Hyundai) is recalling certain 2020-2021 Santa Fe, 2021 Sonata, and Elantra vehicles. During manufacturing, the windshield may not have been properly bonded to the vehicle, allowing it to detach in a crash.
Risk and remedy
Risk
A windshield that detaches from a vehicle during a crash can increase the risk of injury.
Remedy
Dealers will remove and reinstall the front windshield panel, free of charge. Owner notification letters were mailed June 20, 2022. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 216.
Hyundai Motor America (Hyundai) is recalling certain 2021-2022 Santa Fe and Sonata vehicles equipped with 2.5L turbocharged engines. Fuel may leak at the pipe connection between the high-pressure fuel pump and fuel rail.
Risk and remedy
Risk
A fuel leak increases the risk of a fire.
Remedy
Dealers will inspect and tighten, or replace the fuel pipe as necessary, free of charge. Owner notification letters were mailed on September 3, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 207.
Owner complaints
135 complaints7 involved a crash13 injuries
What owners report most
Latest complaints
- Electrical system
The left turn signal works intermittently. It has now stopped working about 90% of the time. The multi-function switch was replaced 3 times and I am still having the issue. The signal won't work on the exterior and it won't light up on the interior dash either. This is creating an unsafe driving…
The left turn signal works intermittently. It has now stopped working about 90% of the time. The multi-function switch was replaced 3 times and I am still having the issue. The signal won't work on the exterior and it won't light up on the interior dash either. This is creating an unsafe driving environment which increases crash rates. Multiple vehicle owner with the same make/model/year are experiencing this issue, which I have found during research.
- Power train
My 2021 Hyundai Sonata N Line suffered a catastrophic, sudden total loss of drive power while operating at speed on a public roadway, creating an immediate crash hazard. The vehicle lost forward propulsion and the gear selector flashed a blinking 'R' when reverse was attempted. The vehicle was…
My 2021 Hyundai Sonata N Line suffered a catastrophic, sudden total loss of drive power while operating at speed on a public roadway, creating an immediate crash hazard. The vehicle lost forward propulsion and the gear selector flashed a blinking 'R' when reverse was attempted. The vehicle was towed to an authorized dealer, [XXX] Hyundai Southtowne, where their factory GDS tool pulled transmission code P283601 (Shift Fork 'B' Position Circuit). This matches the exact critical safety failure path targeted by Federal Safety Recall 236 (NHTSA Campaign 22V-746) for the 8-speed wet-DCT high-pressure electric oil pump circuit failure. The vehicle previously received the 2022 software patch, but the underlying physical hardware has now actively degraded. The dealership is attempting to deny the federal safety recall remedy based on the vehicle's high mileage. An active corporate consumer affairs investigation has been opened under Case #XXX. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
- Fuel/propulsion system
DESCRIPTION OF SAFETY DEFECT & IMMEDIATE HAZARD:My 2021 Hyundai Sonata SEL is currently exhibiting the most severe, catastrophic symptoms of the fuel tank expansion defect covered under NHTSA Campaign 25V796000. The fuel tank has expanded so drastically that it physically warped the structural…
DESCRIPTION OF SAFETY DEFECT & IMMEDIATE HAZARD:My 2021 Hyundai Sonata SEL is currently exhibiting the most severe, catastrophic symptoms of the fuel tank expansion defect covered under NHTSA Campaign 25V796000. The fuel tank has expanded so drastically that it physically warped the structural interior of the cabin, violently popping the rear passenger seat completely out of its assembly while the vehicle was in motion. Furthermore, there is a constant, heavy, raw gasoline odor inside and around the vehicle. The vehicle is a documented, active fire, explosion, and vapor inhalation hazard. It is currently physically located at Sterling Hyundai in Lafayette, LA.DESCRIPTION OF MANUFACTURER NON-COMPLIANCE & REFUSAL TO REMEDY:Hyundai Motor America and Sterling Hyundai are in direct violation of their legal obligation to provide a safe, accessible remedy or interim safety accommodations under federal recall guidelines. An Executive Case Manager from Hyundai Corporate has officially refused to provide a direct-billed rental vehicle or a dealer loaner.Initially, a third-party rental vehicle was provided. However, that vehicle was compromised in an accident and wrecked through absolutely no fault of my own. Despite my lack of fault, Hyundai Corporate and the dealership are now explicitly using that accident to refuse any further direct-billed rental accommodations or dealer loaners.Instead, they are demanding that I pay out-of-pocket for a rental vehicle at a rate of $60/day for a repair process expected to take multiple weeks, knowing I do not possess the upfront financial means to cover these costs. By imposing this insurmountable financial barrier due to an accident I did not cause, Hyundai has effectively stranded me. Because I must maintain my livelihood and have no other means of transportation, Hyundai’s bad-faith refusal to direct-bill an accommodation is actively forcing me to retrieve and operate a verified, explosive fire hazard.REMEDY SOUGHT:I request that the NH
- Fuel system, gasoline
The contact owns a 2021 Hyundai Sonata. The contact received notification of NHTSA Campaign: 25V796000 (Fuel System, Gasoline); however, parts were on back order. The contact stated that while driving at an undisclosed speed, the vehicle jerked with an abnormal gasoline odor inside the vehicle. An…
The contact owns a 2021 Hyundai Sonata. The contact received notification of NHTSA Campaign: 25V796000 (Fuel System, Gasoline); however, parts were on back order. The contact stated that while driving at an undisclosed speed, the vehicle jerked with an abnormal gasoline odor inside the vehicle. An unknown warning light was temporarily illuminated. Upon further inspection, the contact became aware that the fuel level had dropped. The vehicle was taken to a local dealer where it was diagnosed with an expanded fuel tank. The contact stated that the O2 sensor, spark plugs, and ignition coils were replaced by a local independent mechanic; however, the failures persisted. The contact had headaches while driving the vehicle. Medical attention was not needed. The manufacturer was made aware of the failure. The failure mileage was approximately 100,000.
- Power train
Transmission replaced twice and all of them continue to fail. Several Hyundai service centers are unable to determine the cause and are only able to update/relearn and replace whenever they are able to replicate the issue. The issue is that at a cold start, the car makes a popping sound, jerks and…
Transmission replaced twice and all of them continue to fail. Several Hyundai service centers are unable to determine the cause and are only able to update/relearn and replace whenever they are able to replicate the issue. The issue is that at a cold start, the car makes a popping sound, jerks and shakes. The car hesitates to accelerate. You can hear the noise of acceleration but RPM does not go past 3 and MPH doesn't go past 30mph. I'm unable to upload docs because of the upload limit. If there's another way to send docs, please let me know
- Forward collision avoidance › Adaptive cruise control · Power train · Unknown or other
Massive loss of coolant in closed loop cooling system Heat soak. Fail safe mode
- Fuel system, gasoline
The contact owns a 2021 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while driving at an undisclosed speed, the vehicle independently…
The contact owns a 2021 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while driving at an undisclosed speed, the vehicle independently accelerated and decelerated while the accelerator pedal was depressed. The check engine warning light was illuminated. The vehicle was towed to a local dealer where it was diagnosed with an expanded frame due to an expanded fuel tank. The vehicle was deemed too expensive to repair per the local dealer and was towed for a buy-back. The manufacturer was made aware of the failure, but no assistance was provided. The failure mileage was approximately 55,000.
- Fuel/propulsion system
I took my vehicle in for the safety recall due to an expanding fuel tank on 08/03/2026. I received my vehicle back on 8/12/2026. Hyundai performed an improper repair on the vehicle that will not correct the fuel tank expansion. They replaced the same check valve that was replaced last time I…
I took my vehicle in for the safety recall due to an expanding fuel tank on 08/03/2026. I received my vehicle back on 8/12/2026. Hyundai performed an improper repair on the vehicle that will not correct the fuel tank expansion. They replaced the same check valve that was replaced last time I brought the vehicle in for recall on 11/20/2024 repair order # 107221 at Jones Hyundai of Belair. This valve did not and will not correct the fuel tank expansion issue. The expansion issue is caused by fuel getting past the check valve and entering the purge control system. The correct repair is to replace the fuel tank and the purge control system, as the check valve has already allowed fuel to bypass it and enter the system causing the expansion issue. . Replacing the valve that failed & allowed fuel into the system & caused the tank to expand will not correct the issue caused by the failed valve. My fuel tank has not decompressed. I still have the same problem I brought the vehicle in for because the repair Hyundai advised NHTSA on was NOT performed.
- Fuel/propulsion system
Gas tank expansion and pcv melted. Car smells like gas when I was driving earlier, and my garage was flooded with the fumes of gasoline.
- Electrical system
The Left blinker switch keeps going in and out, working about 50% of the time. Both the light and the blinker sound do not turn on. When getting it checked out at an auto repair shop, the maintenance tech said this was more and more common for 2021 sonatas and it was not due to anything I did. It was a multifunction switch problem.
- Fuel system, gasoline
The contact owns a 2021 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the fuel gauge indicated that the tank was half full. The contact stated that the gauge erroneously indicated that the tank was empty, and the check engine warning light was illuminated. The…
The contact owns a 2021 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the fuel gauge indicated that the tank was half full. The contact stated that the gauge erroneously indicated that the tank was empty, and the check engine warning light was illuminated. The vehicle was driven to the gas station, and while attempting to refuel the vehicle, the fuel did not go into the tank. The vehicle was towed to the residence. The vehicle was later towed to the dealer, where it was diagnosed with a failed fuel system and a failed fuel tank. The contact was informed that the fuel system and fuel tank needed to be replaced. The vehicle was not repaired. The contact was informed that the failure was associated with the unrepaired recall. The contact was informed that the vehicle was a fire risk. In addition, the contact was informed that there was a hole in the fuel tank that caused the fuel to leak out of the fuel tank. The contact was informed that the parts were ordered to repair the vehicle. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline). The manufacturer was not made aware of the failure. The failure mileage was approximately 50,200.
- Engine · Power train
Going down the road driving the car lost power and went in limp mode with no warnings on the dash at all!
- Unknown or other
1. Component Failed: Panoramic Sunroof Glass Assembly (Structure / Visibility / Glass). Details: While traveling at highway speed on the freeway, the panoramic sunroof glass spontaneously exploded outward without warning or impact from any foreign object. Inspection: I have not had the vehicle…
1. Component Failed: Panoramic Sunroof Glass Assembly (Structure / Visibility / Glass). Details: While traveling at highway speed on the freeway, the panoramic sunroof glass spontaneously exploded outward without warning or impact from any foreign object. Inspection: I have not had the vehicle repaired yet so it is currently available. I also took a picture of it. 2. Safety Risk: The sudden, loud explosion (sounding like a gunshot) at freeway speeds caused immediate driver distraction and severe disorientation. Shattered tempered glass was mostly restricted from the cabin by the curtain barrier but some rained down into the passenger cabin. Most blew backward onto the highway, posing a major hazard to occupants as well as trailing motorists. Furthermore, this is a recurring defect in our household: my wife experienced an identical spontaneous sunroof explosion on her 2024 Hyundai Palisade, demonstrating a pattern of hazardous glass failures across multiple late-model Hyundai vehicles. 3. Reproduced or confirmed: I have not had it inspected by anyone. I am awaiting quotes for repairs. I have taken a picture of the vehicle that has not been driven since the incident. 4. Inspection: No one else has inspected it. I have a picture and can take more as needed. Hoping to not have to drive it until I take it to a shop for repairs. It has been reported to a dealership, but they did not seem too concerned or interested in helping. They insisted that they would not give a repair quote until I drove it the 20 miles for them to inspect. 5. Any Warning: No warning. There were no warning lights, abnormal noises, visible cracks, or previous symptoms prior to the sudden explosion. The failure occurred completely spontaneously under normal highway driving conditions.
- Fuel/propulsion system
Engine revving at a complete stop. Surging engine while braking. I was forced to put into neutral when stopping. I had check engine prior that read P049D85. It went away. The Hyundai dealer said to be the EGR valve. Nick Hayes at D'Arcy Hyundai and Hyundai Motor America (HMA) agreeing to a 75% goodwill split of cost to repair.
- Fuel system, gasoline
The contact owns a 2021 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 25V796000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not yet available. The contact…
The contact owns a 2021 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 25V796000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The vehicle was taken to the local dealer, and the contact was informed that the fuel tank was swollen and needed to be replaced. The vehicle was not yet repaired. The failure mileage was 80,484.
- Unknown or other
The panoramic sunroof spontaneously exploded while driving without any external impact
- Service brakes
The contact owns a 2021 Hyundai Sonata. The contact stated that while driving 10 MPH and attempting to make a right turn, the brakes independently activated. Neither the dealer nor an independent mechanic was contacted. The check engine warning light was illuminated. The contact stated that the…
The contact owns a 2021 Hyundai Sonata. The contact stated that while driving 10 MPH and attempting to make a right turn, the brakes independently activated. Neither the dealer nor an independent mechanic was contacted. The check engine warning light was illuminated. The contact stated that the failure had occurred on several occasions. The vehicle was taken to the dealer and an independent mechanic to be diagnosed. The manufacturer was not notified of the failure. The approximate failure mileage was 42,000.
- Engine · Fuel/propulsion system
At approximately 130,000 miles, vehicle developed and internal coolant leak caused by a failed Exhaust Heat Recovery System (EHRS) in the center muffler assembly, matching TSB 23-EM-009H - a known manufacturing defect documented by Hyundai. Coolant has been slowly leaking internally into the…
At approximately 130,000 miles, vehicle developed and internal coolant leak caused by a failed Exhaust Heat Recovery System (EHRS) in the center muffler assembly, matching TSB 23-EM-009H - a known manufacturing defect documented by Hyundai. Coolant has been slowly leaking internally into the exhaust system. The authorized Hyundai dealership initially failed to diagnose the internal leak and told me there was no leak and wanted to send me home. After pushing back, the internal leak was confirmed. If not caught, this defect could result in engine overheating or complete engine failure without warning. Hyundai Motor America has denied goodwill coverage despite this being a documented manufacturing defect.
- Power train
The vehicle has experienced repeated transmission and Electronic Oil Pump (EOP) failures resulting in loss of propulsion, loss of acceleration, and transmission-related malfunctions. The vehicle currently has approximately 69,000 miles. On September 3, 2022, the vehicle lost propulsion while…
The vehicle has experienced repeated transmission and Electronic Oil Pump (EOP) failures resulting in loss of propulsion, loss of acceleration, and transmission-related malfunctions. The vehicle currently has approximately 69,000 miles. On September 3, 2022, the vehicle lost propulsion while traveling approximately 31 MPH in traffic and would not respond normally to accelerator input. This created a dangerous situation and increased the risk of a collision. On the same date, while backing out of a parking space, the vehicle displayed a "Shifter System Malfunction" warning message and unexpectedly stopped while in reverse. The vehicle had to be powered off before it would operate again. Following these incidents, the vehicle was towed to a Hyundai dealership and the transmission was replaced in September 2022. Despite the transmission replacement, the vehicle continued experiencing issues involving the same system. The Electronic Oil Pump (EOP) was replaced in 2023 and again in 2024 due to recurring transmission-related concerns and diagnostic codes. In 2026, the check engine light returned and the vehicle was again diagnosed with a transmission-related failure. The dealership determined that the transmission requires replacement for a second time despite the previous transmission replacement and two separate EOP replacements. Internally, Hyundai has since revised its repair guidance for this condition, suggesting that prior repair procedures may not have fully addressed the underlying defect. The repeated failures of the transmission and EOP system despite multiple repairs suggest an underlying defect that has not been corrected. These failures create a significant safety risk because the vehicle can unexpectedly lose propulsion or fail to accelerate while operating in traffic. The vehicle is available for inspection upon request.
- Electrical system · Engine
The car will idle high around 1200 rpms. The car will most of the times fix the issue when you turn the car off and back on but it will start again after driving. This is a known issue with the car. I have had the egr valve replaced since it will pop up the codes P240F and P049 for egr slow…
The car will idle high around 1200 rpms. The car will most of the times fix the issue when you turn the car off and back on but it will start again after driving. This is a known issue with the car. I have had the egr valve replaced since it will pop up the codes P240F and P049 for egr slow response and control position exceeded learning limit but the problem came back within two days. I did find a forum that deals with the joint connector repair but this needs to be a recall as I have come across many people who have this problem and paying out of pocket to fix it.
- Fuel/propulsion system
I took my car to dealer to repair recall. Dealer told me if it failed they would keep car and report stolen if I tried to take it. They failed it. I didn't trust them based on their report it stolen statement. I had the police get my car back. I took it to another dealer where it passed recall easily. I believe they wanted my car for a customer, and tried to get away with this ruse.
- Engine · Fuel system, gasoline
The contact owns a 2021 Hyundai Sonata. The contact stated while driving at an undisclosed speed, the engine shuddered and the engine stalled. In addition, the engine seized. No warning lights were illuminated. The contact stated that the vehicle was seized in the middle of the road. The contact…
The contact owns a 2021 Hyundai Sonata. The contact stated while driving at an undisclosed speed, the engine shuddered and the engine stalled. In addition, the engine seized. No warning lights were illuminated. The contact stated that the vehicle was seized in the middle of the road. The contact stated that while attempting to start the vehicle, the vehicle started. The failure reoccurred. The vehicle was towed to the residence. 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 140,000.
- Engine
The Exhaust Heat Recovery System (EHRS) has failed for the second time on this vehicle. The first failure occurred at approximately 35,000 miles and was repaired under Hyundai Technical Service Bulletin 23-EM-009H, which Hyundai issued to address this exact defect across 2020-2023 Sonata Hybrid…
The Exhaust Heat Recovery System (EHRS) has failed for the second time on this vehicle. The first failure occurred at approximately 35,000 miles and was repaired under Hyundai Technical Service Bulletin 23-EM-009H, which Hyundai issued to address this exact defect across 2020-2023 Sonata Hybrid models. The vehicle has now reached 71,000 miles and is experiencing the identical symptoms: coolant loss, overheating, and white exhaust smoke. The EHRS shares a coolant loop with the hybrid battery thermal management system. Coolant loss from this failure puts the hybrid battery and power electronics at risk of overheating, creating a potential fire and safety hazard. The recurring nature of this failure following an official TSB repair suggests the root cause has not been adequately addressed by Hyundai's current repair protocol.
- Structure › Body · Unknown or other
• I experienced trouble with my splash guard being damaged from hanging and scraping the ground about a month after purchasing the vehicle. Also, my hood paint started chipping after a recent cold front experienced in my state earlier this year. Yes it is available for inspection upon request.…
• I experienced trouble with my splash guard being damaged from hanging and scraping the ground about a month after purchasing the vehicle. Also, my hood paint started chipping after a recent cold front experienced in my state earlier this year. Yes it is available for inspection upon request. Regarding the splash guard, not applicable. • It’s was very inconvenient to drive with a portion of my car scraping the ground. I had to be more mindful of my driving in the higher speed limit areas incase the splash guard detached. I had it re-attached multiple times. Regarding the chipped paint, not applicable. • It it counts, for my splash guard, during a servicing, I asked Hyundai to re-attach it. For the chipped paint, no. • The splash guard has during a past servicing. The chipped paint is more recent so it hasn’t • No. Splash guard, a month after purchasing vehicle. The chipped paint, earlier this year, January-February 2026.
- Fuel/propulsion system · Unknown or other
I was notified of a recall on my from vehicle by Hyundai via email some time in March of 2026. The message said mentioned my vehicle may have a defective/worn purge control check valve that would cause the fuel tank to deform. Potentially leading to a release of fuel over time, which then could…
I was notified of a recall on my from vehicle by Hyundai via email some time in March of 2026. The message said mentioned my vehicle may have a defective/worn purge control check valve that would cause the fuel tank to deform. Potentially leading to a release of fuel over time, which then could ignite. NHTSA Recall #25V796000 My car showed now signs of problems, but I brought it into a Hyundai dealership on March 13th where they confirmed my vehicle had the issue. They said the situation required I not drive my vehicle and gave me a rental in the meantime. I assumed it would be a simple swap of the fuel tank and everything would be fine. I was offered a buyback from my Hyundai claims manager over the situation, but I figured since its a simple fix, I'd keep my car and have it fixed. Two weeks went by with no update from the dealership, so I walked in for answers. Turns out, the subframe of my car has been damaged by the expanding fuel tank and they are still waiting for updates from Hyundai on how to proceed as they themselves don't know how to fix my vehicle. My Hyundai claims manager did not mention this when we talked over the phone and he offered a buyback. None of their recall notices mention structural damage anywhere or even as a possibility. I asked the dealership again on April 1, 2026, and they are still waiting on guidance on how to proceed. Neither does my Hyundai claims manager handling this situation on their end.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Loss of Motive Power
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…
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.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11011830The subject vehicles may have Diagnostic Trouble Code (DTC) P0451 stored in the ECU, which could cause the Check Engine Lamp to come on.
- 11010975Certain 2021-2023MY Sonata (DN8) and 2020-2022MY Sonata (DN8A) vehicles may have Diagnostic Trouble Code (DTC) P0451 stored in the Electronic Control Unit (ECU). The California Air Resources Board has determined that these vehicles may be releasing air pollutants which exceed Federal and California standards.
- 11010974Certain 2021-2023MY Sonata (DN8) and 2020-2022MY Sonata (DN8A) vehicles may have DTC P0451 stored in the ECU. Follow this bulletin to inspect the check valve, fuel pump cover and fuel tank, and update the ECU. If necessary, replace the check valve and/or fuel tank based on inspection results.
- 11006112Certain 20-22MY Sonata (DN8a), 21-23MY Santa Fe (TMa), and 22-23MY Tucson (NX4a) vehicles may experience a warning lamp illumination for a diagnostic trouble code P2181 that is related to the Integrated Thermal Management Module (ITM). Follow the service procedure outlined in this bulletin to replace the ITM.
- 11006111Some vehicles equipped with the AVN 5th Gen Wide system may exhibit a condition where the radio app crashes frequently when entering radio mode and/or displays a message that reads Uneven Road Ahead, Drive carefully on the cluster along with a warning sound. Follow the procedure outlined in this bulletin to update the AVN software to resolve this condition.
- 10253275This TSB provides a procedure to diagnose and replace, if necessary, an automatic transmission with Incorrect Ratio DTC (transmission clutch slip in gear above limit) listed on Page 2.
- 10251294This bulletin provides the procedure to update the Engine Control Module (ECM) and/or the Transmission Control Module (TCM) for 2020-2023MY Sonata (DN8/DN8a) vehicles to improve operation of the Idle Stop and Go (ISG) system. Under certain circumstances the vehicle may not restart after the ISG system has engaged and requires a manual restart due to the lack of intake manifold pressure recovery.
- 10251293This bulletin provides the procedure for updating the automatic transmission TCU and ECU software (Santa Fe ONLY) to improve shift quality, judder with ISG enabled and hesitation when accelerating.
- 10251285This bulletin contains information about the proper removal of the windshield wiper blade protective cover on all models. If the protective cover is not removed correctly, there is a possibility of the rubber insert and rail spring becoming partially separated on the inner side of the wiper blade, which could lead to poor wiping performance and/or possible scratching of the windshield glass. Follow the procedure in this bulletin to properly remove the windshield wiper blade protective cover on all new wiper blades.
- 10249699Some vehicles equipped with the AVN 5th Gen Wide system may exhibit a condition where the radio app crashes frequently when entering radio mode and/or displays a message that reads Uneven Road Ahead, Drive carefully on the cluster along with a warning sound. Follow the procedure outlined in this bulletin to update the AVN software to resolve this condition.
- 10247189This bulletin provides important checkpoint guidelines when performing engine oil and filter change services.
- 10245580This TSB provides information to diagnose the push button shifter operation.
- 10243340This bulletin is issued to provide the extended battery diagnosis procedure using GDS-M. This battery diagnosis function displays the various battery-related faults such as: Internal short circuit Battery deterioration Malfunction of electronic parts Insufficient battery charge Normal battery Charging defect Battery diagnosis uses the battery sensor history saved for the last 30 days and ICU diagnostic communication to track battery state of charge (SOC) and current parasitic draw history.
- 10243329If you are servicing an 8-speed front-wheel-drive vehicle equipped with automatic transaxle with one or more of the DTC or symptoms listed below, refer to the Service Procedure to diagnose the condition. DIAGNOSTIC TROUBLE CODES: P070500 - Transmission range sensor circuit malfunction P070512 - Transmission range sensor circuit malfunction P070514 - Transmission range sensor circuit malfunction P07051C - Transmission range sensor circuit malfunction P070600 - Transmission range sensor circuit range/performance P070661 - Transmission range sensor circuit range/performance P070696 - Transmission range sensor circuit range/performance SYMPTOMS: Malfunction Indicator Light (MIL) illuminated 5th gear fail-safe Intermittently wont shift into D or R Intermittently wont shift out of Park Intermittent ly no engine cr ank/n o start in P or N with or without MIL or DTC.
- 10241891This bulletin outlines changes to the service procedure regarding the replacement of 8-speed wet dual clutch transmissions (8WDCT) and associated transmission control unit (TCU). These changes only apply to vehicles equipped with Theta 2.5T engines. Certain transmissions (indicated by a new part number) have received an improved clutch spring. The correct TCU software update must be matched with the correct corresponding 8WDCT hardware, otherwise drivability concerns may occur.
- 10241890This bulletin provides information related to a Transmission Control Unit (TCU) software update for certain vehicles equipped with an 8-speed wet dual clutch transmissions (8WDCT) that improves the touch point learning variation. Certain 8WDCTs (indicated by a new part number) received an improved clutch spring. The correct TCU software update must be matched with the correct corresponding 8WDCT hardware, otherwise drivability concerns may occur.
- 10241885If you are servicing an 8-speed vehicle with a Check Engine light on and one or more of the DTC listed, follow the service procedure and replace the related solenoid and harness.
- 10241875This bulletin provides warranty procedure for EGR Valve replacement related to DTC P0401 EGR Flow Insufficient on 2020 and 2021MY Sonata (DN8a) equipped with 2.5 GDI Vehicles.
- 10241796This TSB provides information to diagnose the push button shifter operation. If you are servicing a vehicle with any symptoms listed below or DTCs (listed on Page 2) , follow the Service Procedure on Page 3. SYMPTOMS: Shifter System Malfunction displayed in the cluster Wont shift into or out of gear or wont shift out of Park Incorrect gear display in cluster and/or wont start
- 10240089If you are servicing an 8-speed DCT front-wheel-drive vehicle with the DTC or symptoms listed below, refer to the Service Procedure to diagnose the condition. DIAGNOSTIC TROUBLE CODES: P070500 - Transmission range sensor circuit malfunction P070512 - Transmission range sensor circuit malfunction P070514 - Transmission range sensor circuit malfunction P07051C - Transmission range sensor circuit malfunction P070600 - Transmission range sensor circuit range/performance P070661 - Transmission range sensor circuit range/performance P070696 - Transmission range sensor circuit range/performance SYMPTOMS: Malfunction Indicator Light (MIL) illuminated 5th gear fail-safe Intermittently wont shift into D or R Intermittently wont shift out of P Intermittent ly no engine crank in P or
- 10240087This Service Information bulletin provides information on how to update the Apple Carplay software from Hyundais Navigation Updates page. The current version of Google Maps has 10 times the data transmission compared to the previous version. As a countermeasure, an update with a frame skip logic has been added to resolve the data congestion with Google Maps.
- 10240084If you are servicing an 8-speed front-wheel-drive vehicle equipped with automatic transaxle with one or more of the DTC or symptoms listed below, refer to the Service Procedure to diagnose the condition.
- 10238377This bulletin provides the diagnostic procedure for the GDI injector(s) in certain 21-23MY Sonata, 21-22MY Santa Fe, certain 22MY Santa Cruz, and certain 21-23MY Tucson equipped with 2.5L GDI engines with one or more misfire DTC(s) due to internally leaking GDI injector(s)
- 10237183This bulletin provides service procedures to prevent possible moisture intrusion of the HP EOP (High Flow Electric Oil Pump) connector when servicing the 8-speed wet dual clutch transmission (8WDCT). If moisture enters the HF EOP connector, this can result in corrosion and insufficient connection of the terminals.
- 10237182This TSB applies only if Recall 236 or Service Campaign T8N has been performed and the 8 speed wet dual clutch transmission (8WDCT) replacement is necessary related due to high pressure electric oil pump (HP EOP) DTCs P1C2D03 (HP EOP Motor Position Sensor), P193B79 - HP EOP Performance, P0868 - Transmission Fluid Pressure (TFP) Sensor Low. Replace the 8WDCT under this bulletin.
- 10235566Hyundai applies a Paint Protection Film (PPF) on new vehicles before delivery to dealerships. It provides a barrier between the paint and contaminants, such as rail dust, acid rain, and industrial fallout. In rare cases, the paint can become clouded under the PPF. These spots are the result of moisture trapped between the PPF and the paint.
- 10235344This bulletin provides the procedure to repair poor pin tension at joint connector JE102 in certain Sonata (1.6 T-GDI engine) with one or more DTC.
- 10235343This bulletin provides the procedure to repair poor pin tension at joint connector JE202 in certain Sonata (2.5L GDI engine) with one or more DTC.
- 10235340If you are servicing an 8-speed vehicle with a Check Engine light on and one or more of the DTC listed, follow the service procedure and replace the related solenoid and harness.
- 10233552This bulletin provides the diagnostic procedure for the GDI injector(s) in certain 21-23MY Sonata, 21-22MY Santa Fe, certain 22MY Santa Cruz, and certain MY21-23 Tucson equipped with 2.5L GDI engines with one or more misfire DTC(s) due to internally leaking GDI injector(s).
- 10230912Some 2021 ~ 2022MY Sonata (DN8/DN8a) vehicles with N-Line trim may not engage Forward Collision Avoidance Assist Junction Turning (FCA-JT) due to omitted logic.
- 10230904This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation.
- 10225470This bulletin provides the diagnostic procedure for the GDI injector(s) in certain 21-22MY Sonata, Santa Fe, and certain 22MY Santa Cruz, and Tucson equipped with 2.5L GDI engines with one or more misfire DTC(s) due to internally leaking GDI injector(s).
- 10225459This bulletin outlines changes to the service manual regarding the replacement of 8-speed dual clutch transmissions (DCT) and associated transmission control module (TCM). Additional steps, not in the service manual, are required within GDS prior to replacing the DCT/TCM, otherwise drivability concerns and/or DTCs may occur.
- 10218647This bulletin provides the procedure to update the TCU software to improve drivability and shift quality.
- 10217258Effective June 2, 2008, Federal Motor Vehicle Safety Standard 110 (FMVSS 110) established a threshold for correcting load carrying capacity information indicated on tire placards when vehicle weight has been increased before retail sale. This limit is the lesser of 1.5% of GVWR or 100 pounds. If the total added weight exceeds the lesser of the limit, a label must be added to the driver-side B-pillar within 25mm (1 inch) of the original tire placard.
- 10217251Follow the guidelines outlined in this bulletin to inspect and clean or replace certain components of the engine intake system accordingly during engine short block or sub-assembly replacement.
- 10217250If you are servicing an applicable vehicle with a Check Engine light on and one or more of the DTC listed on Page 2, follow the repair procedure and perform the diagnosis. If necessary, replace the High Flow electric oil pump (HF EOP) for HF EOP issues or the Dual Clutch Transmission for High Pressure electric oil pump (HP EOP) issues.
- 10215599Certain vehicles may develop a bearing noise within the Motor Driven Power Steering (MDPS) column worm shaft assembly. If bearing noise is heard, follow the procedure in this bulletin to replace the worm shaft bearing.
- 10211677Certain 2020-2022MY Sonata (DN8A) vehicles may develop a bearing noise within the Motor Driven Power Steering (MDPS) column worm shaft assembly. If bearing noise is heard, follow the procedure in this bulletin to replace the worm shaft bearing.
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