2023 Hyundai Tucson Hybrid

I am reporting a critical Exhaust Gas Recirculation (EGR) valve failure on my 2023 Hyundai Tucson Hybrid. The failure resulted in an immediate loss of engine power, reduced vehicle performance, reduced fuel efficiency, and the vehicle entering limp mode while driving, creating a significant safety hazard in traffic. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) were confirmed during diagnostic inspection. Root Cause: The component failure is directly linked to an internal short circuit in the EGR valve assembly, caused by solder flux contamination during manufacturing. Manufacturer Response & Escalation Denial: When contacting Hyundai regarding this failure, I was informed that my vehicle’s VIN is "not included in Safety Recall 260" (NHTSA Campaign 24V-308). I formally escalated this claim to Hyundai Corporate, but my request for reimbursement and coverage was explicitly denied on the grounds that my VIN falls outside the designated recall parameters. However, this exact failure mode, part assembly line, and manufacturing defect (solder flux contamination) are identical to the safety defect described in Recall 260 as well as Hyundai Service Campaign 9B3. Hyundai is restricting coverage based on narrow VIN manufacturing windows despite identical, defective parts being installed across non-recalled vehicles. Because a sudden EGR failure causes unexpected loss of power while traveling in traffic, and because Hyundai Corporate has refused to cover this out-of-pocket repair, I am requesting that NHTSA investigate this issue and compel Hyundai to expand the scope of Recall 260 to protect affected owners and mandate reimbursement for out-of-pocket repair costs.

1. Sometimes vehicle does not start. Only starts if battery reset button pushed. 2. Sometimes vehicle while moving has delayed braking after juddering. Only stops when car stopped and restarted. 3. Sometimes vehicle while moving suddenly revs, RPMs spike until car stopped and restarted. Engine revs but does not shoot forward. 4. Spookiest of all, while moving car suddenly stops accelerating. Pedal on the floor and it is coasting to a stop. When car stopped, and turned off, then it will work. Had we been on the interstate we would have died, These incidents were sporadic and occurred on and off during the month of April and May. Each of the above occurred numerous times to different drivers. Service at two locations were unable to ID. We sold the moving death trap to one of the Hyundai dealers who could find no mechanical problems with the vehicle. The vehicle was terrifying to drive. There are other reports on this vehicle of these issues ... which appear to be electronic. Hyundai has good engineers. They know what is causing this and simply do not want to replace a very expensive but obviously failing electronic control module.

The ABS, ! Brake and Auto Hold lights activated. I took in into the Hyundai Joplin, MO dealership on May 2, 2024. They could not find any thrown codes and suggested it was most likely the "IEB Module" which they replaced and after doing so, the warning lights remained activated. As of May 22, 2024, they are ordering a new IEB Module to install (backordered into June). This seems oddly similar to previous ABS and brake problems of earlier models and makes me feel uneasy with the safety of this vehicle should they ever get it remedied.

Unknown what fails. After driving approximately 30 minutes on a highway, car suddenly stops accelerating and bucks a bit as it slows. Must turn off car and turn it back on to accelerate again. Happens on the highway frequently. Very dangerous as there’s no way to accelerate. Only stop. It’s like it can’t find a gear and the engine revs. It happened 6 times during a 2.5 hour drive.