2020 Hyundai Sonata

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed with the family inside the vehicle, a strong gasoline odor was inside the cabin of the vehicle. The contact stated that the fuel gauge was lowering quickly. Upon exiting the vehicle, the contact became aware of gasoline gushing heavily out of the vehicle onto the ground. Two months prior to the failure, the vehicle was taken to an authorized dealer due to an abnormal sound coming from the rear of the vehicle. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the recall repair was not performed because the part for the recall repair was not yet available. The vehicle was towed to a dealer where it was determined that the gas valve was not properly fixed. The abnormal sound in the rear of the vehicle was due to the fuel expansion, which caused the tank to rupture and melt. The melting caused the fuel pump to expand and melt, causing structural damage to the body of the vehicle. The structural expansion caused the rear passenger seats to raise up. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 89,000.

The contact owns a 2020 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 25V796000 (FUEL SYSTEM, GASOLINE). The contact stated that while driving 60 MPH, the vehicle was leaking fuel from the fuel tank. There was no warning light illuminated. The dealer was contacted and notified of the failure, and the vehicle was repaired. The contact stated that the failure was a recurring failure. The manufacturer was notified of the failure. The failure mileage was approximately 108,000.

The contact owns a 2020 Hyundai Sonata. The contact stated that the fuel failed to go into the tank. The seat failed to move. The engine light illuminated. The vehicle stalled. While driving, the fuel gauge went from full to empty. The contact received the NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline) after the failure. The vehicle was towed to the local where it was diagnosed that the fuel tank had expanded. The vehicle was repaired approximately eight months later. The contact called another local dealer. Ourisman Hyundai Bowie, 2404 Crain Hwy A, Bowie, MD 20716, who was unable to schedule an appointment. The manufacturer instructed the dealer to keep the vehicle due to it being a fire risk. The manufacturer was contacted regarding a buyback. The failure mileage was approximately 80,000.

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, who retrieved a diagnostic trouble code for the check valve. The mechanic related the failure to NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline), associated with the VIN; however, the contact had not received notification of the recall. The vehicle was then taken to the dealer, who determined that the check valve had failed and the fuel tank was deformed. The contact was referred to the manufacturer. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was filed. The manufacturer offered to buy back the vehicle, but the contact declined the offer. The failure mileage was approximately 82,000.

The contact owns a 2020 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 local dealer was contacted. 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 contact had not experienced a failure.

The contact owns a 2020 Hyundai Sonata. The contact stated that while attempting to start the vehicle, the vehicle failed to start. The battery and the key warning lights were illuminated. The contact stated that after several attempts, the vehicle started. The vehicle was driven to the end of the driveway and turned off. The contact was afraid of driving the vehicle due to the failure. The independent mechanic was made aware of the failure. The contact was informed of an open recall. The dealer was made aware of the failure and confirmed the open recall information. In addition, the contact was advised that the failure might be because of the unrepaired recall. The contact was advised to bring the vehicle in for diagnostic testing. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, parts for the recall repair were not yet available. The failure mileage was approximately 42,947.

The contact owns a 2020 Hyundai Sonata. The contact stated while driving at 35 MPH, the vehicle made a booming sound. There were no warning lights illuminated. The contact then started to hear the sound outside the vehicle and noticed that the vehicle was losing gasoline very quickly. The vehicle started to stall, and the gas tank was almost empty when the contact arrived home. The vehicle was then taken to a dealer where it was diagnosed with floor damage, and the floor damage showed deformation on the rear passenger’s seat, and the fuel cover had popped off due to the deformation, which caused the noise in the cabin. The vehicle was towed to another dealer where the vehicle was repaired, with a new fuel pump cover, and the rear seats were replaced. On another occasion, the fuel pump failure reoccurred. The manufacturer was made aware of the failure. The failure mileage was approximately 77,524.

The contact owns a 2020 Hyundai Sonata. The contact stated while the contact was refueling the vehicle, the fuel was coming back out of the fuel tank onto the ground surface. The contact stated that the failure had occurred while traveling out of town. In addition, the contact stated that the failure had occurred several times and the check engine warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed a failed fuel tank sensor. The contact was informed that the fuel tank sensor light. The contact stated that when the independent mechanic pulled out the rear seat to perform the repair, the mechanic noticed that the metal sheet under the rear seat was fractured due to the pressure of the fuel tank. The vehicle was not repaired. The contact was advised to take the vehicle to the dealer. The vehicle was taken to the dealer, however the dealer declined the repair. The contact was advised not to drive the vehicle and informed that the vehicle was a ticking bomb. In addition, the contact was advised to take the vehicle to a collision shop, prior to the repair being performed. The vehicle was not repaired or diagnosed by an independent mechanic or the dealer. The contact's insurance declined the repair stating that the failure was due to a manufacturer defect. The manufacturer was made aware of the failure and a case was filed. In addition, the contact was informed that the repair was not covered under warranty because the contact was the second owner of the vehicle. In addition, the contact's vehicle mileage was above the 60,000 mileage warranty coverage. The failure mileage was approximately 99,230.

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, there was an abnormal gasoline odor inside the vehicle, after which the vehicle lost motive power. The contact pulled over to the shoulder of the roadway, moved the rear seat, and observed that the fuel pump was protruding upwards. The check engine warning light was illuminated. The vehicle was towed to the dealer, who diagnosed a failure with the purge valve, resulting in damages to the fuel pump and fuel tank. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 47,000.