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2011 Hyundai Tucson

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2011 Hyundai Tucson do not stand out strongly from the model-year median of 180.5.

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When problems were reported

Mileage at the reported incident

70 reports with mileage · 54 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

5 crash reports3 fire reports3 injury reports

Power Train complaints

20 reports
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45,909 miles · Nov 7, 2013
Power Train

WHILE DRIVING MY 2011 HYUNDAI TUCSON MANUAL STICK SHIFT ON THE FREEWAY IN 5TH GEAR, THE CLUTCH CAME APART. ACCORDING TO THE SERVICE TECH, THE CLUTCH HAD NO SIGNIFICANT OWNER WEAR AND TEAR. HE INFORMED ME THAT THE CLUTCH WAS DEFECTIVE AND THAT IT FELL APART WHILE DRIVING BECAUSE A PIECE FELL OUT, WHICH, ACCORDING TO HIM, SHOULD…

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WHILE DRIVING MY 2011 HYUNDAI TUCSON MANUAL STICK SHIFT ON THE FREEWAY IN 5TH GEAR, THE CLUTCH CAME APART. ACCORDING TO THE SERVICE TECH, THE CLUTCH HAD NO SIGNIFICANT OWNER WEAR AND TEAR. HE INFORMED ME THAT THE CLUTCH WAS DEFECTIVE AND THAT IT FELL APART WHILE DRIVING BECAUSE A PIECE FELL OUT, WHICH, ACCORDING TO HIM, SHOULD NEVER HAVE HAPPENED. PICTURES OF DEFECTIVE CLUTCH AVAILABLE. *FOUR MONTHS PRIOR, THE CLUTCH SENSOR WENT OUT AND THE VEHICLE WOULD NOT START. I WAS INFORMED THAT THE VEHICLE HAD A FAULTY SENSOR, AGAIN DUE TO PRODUCT DEFECT. *TR

NHTSA ODI #10551444

18,275 miles · Aug 16, 2013
Electronic Stability Control (esc)Power Train

WHILE DRIVING AT APPROX. 45 MPH, I NOTICED THAT THE ELECTRONIC STABILITY CONTROL LIGHT WAS ON AND THE DOWNHILL BRAKE CONTROL INDICATOR (RED) WAS ON. I RETURNED HOME, SHUT DOWN THE ENGINE, RESTARTED IT, AND THE PROBLEM SEEMED TO GO AWAY. UPON RETURNING HOME THE NEXT DAY FROM A TRIP, WHILE PARKING THE CAR, BOTH INDICATORS CAME ON,…

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WHILE DRIVING AT APPROX. 45 MPH, I NOTICED THAT THE ELECTRONIC STABILITY CONTROL LIGHT WAS ON AND THE DOWNHILL BRAKE CONTROL INDICATOR (RED) WAS ON. I RETURNED HOME, SHUT DOWN THE ENGINE, RESTARTED IT, AND THE PROBLEM SEEMED TO GO AWAY. UPON RETURNING HOME THE NEXT DAY FROM A TRIP, WHILE PARKING THE CAR, BOTH INDICATORS CAME ON, AND THE VEHICLE WOULD NOT ALLOW ME TO PUT THE TRANSMISSION INTO PARK. I LEFT THE TRANSMISSION IN NEUTRAL, AND SHUT THE ENGINE DOWN. I THEN TURNED THE KEY ON, PUT MY FOOT ON THE ACCELERATOR PEDAL (TO THE FLOOR) FOR 3 SECONDS, TURNED THE KEY ON, AND THE PROBLEM WAS GONE....FOR NOW. *TR

NHTSA ODI #10535757

66,000 miles · Aug 14, 2013
Electrical SystemElectronic Stability Control (esc)Power Train

INCLINE AND TRACTION CONTROL LIGHTS ILLUMINATED ON DASH, SIGNALING AN ELECTRICAL PROBLEM. DISCOVERED THAT EXTERIOR BRAKE LIGHTS FAILED TO ILLUMINATE UPON DEPRESSION OF BRAKE PEDDLE, OR WOULD WORK INTERMITTENTLY. ALSO DISCOVERED THAT WHILE THE VEHICLE WAS IN THIS CONDITION, THE CAR WOULD NOT ALLOW THE GEAR SHIFT TO GO INTO PARK…

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INCLINE AND TRACTION CONTROL LIGHTS ILLUMINATED ON DASH, SIGNALING AN ELECTRICAL PROBLEM. DISCOVERED THAT EXTERIOR BRAKE LIGHTS FAILED TO ILLUMINATE UPON DEPRESSION OF BRAKE PEDDLE, OR WOULD WORK INTERMITTENTLY. ALSO DISCOVERED THAT WHILE THE VEHICLE WAS IN THIS CONDITION, THE CAR WOULD NOT ALLOW THE GEAR SHIFT TO GO INTO PARK. THIS WAS A VERY DANGEROUS CONDITION FOR THIS VEHICLE AND COULD HAVE RESULTED IN THE VEHICLE BEING REAR ENDED DUE TO THE INOPERABLE BRAKE LIGHT INDICATORS. *TR

NHTSA ODI #10535287

65,000 miles · Jun 7, 2013
Electronic Stability Control (esc)Power Train

WHEN DRIVING TO AND FROM WORK (AM/PM) THE DBC (DOWNHILL BRAKE CONTROL) AND ESC (ELECTRONIC STABILITY CONTROL) INDICATOR LIGHTS WILL TURN ON AND REMAIN ON UNTIL I STOP AND TURN OFF THE IGNITION. WHEN I STOP, I AM UNABLE TO SHIFT THE GEAR INTO PARK. WHILE IN A PANIC, I MADE SEVERAL ATTEMPTS TO PUT THE VEHICLE IN PARK AND EACH ATTE…

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WHEN DRIVING TO AND FROM WORK (AM/PM) THE DBC (DOWNHILL BRAKE CONTROL) AND ESC (ELECTRONIC STABILITY CONTROL) INDICATOR LIGHTS WILL TURN ON AND REMAIN ON UNTIL I STOP AND TURN OFF THE IGNITION. WHEN I STOP, I AM UNABLE TO SHIFT THE GEAR INTO PARK. WHILE IN A PANIC, I MADE SEVERAL ATTEMPTS TO PUT THE VEHICLE IN PARK AND EACH ATTEMPT WAS UNSUCCESSFUL. SO I PUT IT IN NEUTRAL TO TURN THE IGNITION OFF, WAITED A FEW MINUTES, THEN RESTARTED IT AND PUT IT IN PARK IN ORDER TO REMOVE THE IGNITION KEY. I MAY HAVE TO TRY THIS SEVERAL TIMES BEFORE I AM ABLE TO SHIFT INTO PARK. IT HAS HAPPENED SEVERAL TIMES SINCE THE FIRST DATE. ALSO, WHEN I SHIFT GEARS A LOUD MECHANICAL CLUNK SOUNDS WHICH JERKS THE ENTIRE VEHICLE. THIS EVEN HAPPENS WHEN I START OFF DRIVING AND IT IS VERY ANNOYING AND SCARY. I HAVE TO RESTART THE VEHICLE SEVERAL TIMES BEFORE IT FINALLY STOP. THEN AFTER ABOUT THREE DAYS IT START ALL OVER AGAIN. I SEE THIS AS A DANGER BECAUSE I COMMUTE 56 MILES ONE WAY TO WORK AND I THOUGHT I WAS PURCHASING A DEPENDABLE VEHICLE BUT APPARENTLY NOT. *TR

NHTSA ODI #10515768

27,800 miles · May 11, 2013
Electronic Stability Control (esc)Power Train

WHILE DRIVING IN STOP AND GO TRAFFIC TO AND FROM WORK (AM/PM) THE DBC (DOWNHILL BRAKE CONTROL) AND ESC (ELECTRONIC STABILITY CONTROL) INDICATOR LIGHTS WILL TURN ON AND REMAIN ON UNTIL I STOP AND TURN OFF THE IGNITION. HOWEVER, WHEN I STOP, I AM UNABLE TO SHIFT THE GEAR INTO PARK. I AM FORCED TO PUT IT IN NEUTRAL TO TURN THE IG…

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WHILE DRIVING IN STOP AND GO TRAFFIC TO AND FROM WORK (AM/PM) THE DBC (DOWNHILL BRAKE CONTROL) AND ESC (ELECTRONIC STABILITY CONTROL) INDICATOR LIGHTS WILL TURN ON AND REMAIN ON UNTIL I STOP AND TURN OFF THE IGNITION. HOWEVER, WHEN I STOP, I AM UNABLE TO SHIFT THE GEAR INTO PARK. I AM FORCED TO PUT IT IN NEUTRAL TO TURN THE IGNITION OFF, WAIT A FEW MINUTES, THEN START THE CAR AND PUT IT IN PARK IN ORDER TO REMOVE THE IGNITION KEY. I MAY HAVE TO TRY THIS SEVERAL TIMES BEFORE I AM ABLE TO SHIFT INTO PARK. IT HAS HAPPENED THREE DAYS IN A ROW. THE DEALERSHIP IS UNABLE TO DUPLICATE THIS PROBLEM. THEY DID TELL ME THAT THIS IS A KNOWN PROBLEM WITH THE BRAKE SWITCH FOR SOME MODELS BUT MY VIN# IS NOT SHOWING A RECALL. I WILL NEED TO BRING IN THE CAR WHEN IT ACTUAL LOCKS IN GEAR. *TR

NHTSA ODI #10511497

8,000 miles · Mar 28, 2013
Electrical SystemPower TrainService Brakes

COMMENT: I HAVE BROUGHT IN MY TUCSON FOR THE CLUNKING TRANSMISSION ISSUE 5 TIMES NOW. EACH RETURN TO THE SERVICE CENTER RESULTS IN A CANNOT DUPLICATE RESPONSE. 1. ON THE MORNING OF 28 MARCH 2013, APPROXIMATELY 20 SECONDS AFTER STARTING THE VEHICLE THE TRANSMISSION WAS SHIFTED INTO DRIVE, A LOUD MECHANICAL CLUNK WAS HEARD …

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COMMENT: I HAVE BROUGHT IN MY TUCSON FOR THE CLUNKING TRANSMISSION ISSUE 5 TIMES NOW. EACH RETURN TO THE SERVICE CENTER RESULTS IN A CANNOT DUPLICATE RESPONSE. 1. ON THE MORNING OF 28 MARCH 2013, APPROXIMATELY 20 SECONDS AFTER STARTING THE VEHICLE THE TRANSMISSION WAS SHIFTED INTO DRIVE, A LOUD MECHANICAL CLUNK WAS HEARD AND FELT FROM THE DRIVER'S SEAT, THE TRANSMISSION DID NOT RESPOND, THE VEHICLE WOULD NOT MOVE WHEN THE GAS PEDAL WAS DEPRESSED, AND THE P,R,N,D INDICATOR IN THE DASH BOARD DISPLAY WENT BLANK. THE CAR WAS SHIFTED INTO P, A LOUD MECHANICAL CLUNK' WAS HEARD AND FELT FOLLOWED BY A LOUD CRUNCH'. THE IGNITION WAS TURNED OFF, AND THE VEHICLE WAS RESTARTED WITH NO ISSUES ONCE THE VEHICLE WAS WARMED UP. 2. RECALL SERVICE FOR THE TRANSMISSION COOLING LINE COUPLING PERFORMED, THE VEHICLE BEGAN EXIBITING THE TRANSMISSION DISENGAGE AND REENGAGE SYMPTOM WHILE DRIVING UNDER ACCELERATION. THIS OCCURS APPROXIMATELY ONCE A DAY UNDER ANY INCLINE OR FLAT CONDITION WHILE ACCELERATING. 3. WHILE ACCELERATING UP HILL, SPECIFICALLY UP HILL WHILE ACCELERATING UP TO 45 MPH THE VEHICLE WILL DOWN SHIFT TO CLIMB THE HILL. UNDER 2 CONDITIONS 1. CRUISE CONTROL ENGAGED, 2. CONSTANT ACCELERATOR PEDAL APPLICATION.THE VEHICLE WILL NOT RE-UPSHIFT ONCE THE HILL HAS BEEN COMPLETED AND KEEPS AN ELEVATED RPM RANGE OF APPROXIMATELY 3000 RPM EVEN WHILE ON LEVEL GROUND WHILE PASSING TAX AND REVENUE. THE RPMS DO NOT LOWER AND THE TRANSMISSION WILL NOT UP SHIFT UNTIL EITHER THE BRAKE PEDAL IS DEPRESSED (TO DISENGAGE THE CRUISE CONTROL), OR THE ACCELERATOR IS LIFTED. NOTE: THE ENTIRE TIME THIS SITUATION IS OCCURRING THE ECON GREEN LIGHT IS ILLUMINATED.. THE SAFETY ISSUE IS THAT THE TRANSMISSION INTERMITTENTLY DISENGAGES WHILE DRIVING, SOMETIMES WHILE DEPARTING INTERSECTION. THE TRANSMISSION ROBLEM HAS CONTINUED AND GROWN WORSE WITH EXAPNDING PROBLEMS. *TR

NHTSA ODI #10504783

Mileage unknown · Sep 25, 2012
Exterior LightingPower Train

2011 HYUNDAI TUSCAN. CONSUMER WRITES IN REGARDS TO COOLING LINES, TRANSMISSIONS AND BRAKE SWITCHES REPLACEMENTS MORE THAN ONCE. *TGW THE CONSUMER STATED THE VEHICLE WOULD NT ACCELERATE WHEN THE ACCELERATOR PEDAL WAS APPLIED, THE TRANSMISSION WOULD BUCK AND BANG WHEN IT WAS SHIFTED FROM PARK TO DRIVE. THE DEALER FOUND THE TRAN…

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2011 HYUNDAI TUSCAN. CONSUMER WRITES IN REGARDS TO COOLING LINES, TRANSMISSIONS AND BRAKE SWITCHES REPLACEMENTS MORE THAN ONCE. *TGW THE CONSUMER STATED THE VEHICLE WOULD NT ACCELERATE WHEN THE ACCELERATOR PEDAL WAS APPLIED, THE TRANSMISSION WOULD BUCK AND BANG WHEN IT WAS SHIFTED FROM PARK TO DRIVE. THE DEALER FOUND THE TRANSMISSION WAS WORN INTERNALLY AND THE COOLER HOSE WAS CRACKED, WHICH CAUSED THE TRANSMISSION FLUID TO LEAK. THE ESC LIGHT ILLUMINATED, DUE TO AN OPEN CIRCUIT IN THE BRAKE SWITCH. THE CONSUMER STATED THE VEHICLE WAS TAKEN TO THE DEALER FOR THE SAME PROBLEMS SEVEN TIMES. *JB

NHTSA ODI #10477689

27,000 miles · Sep 8, 2012
Power Train

WHEN RETURNING HOME FROM STORE I COULDN'T PUT THE CAR IN PARK. ONLY COULD GET TO NEUTRAL. TURNED THE CAR OFF AND STARTED IT UP AGAIN AND IT MOVED INTO PARK. THIS HAS HAPPEN NOW THREE(3) TIMES IN THE LAST WEEK. I HAVE CALLED TO GET IT LOOKED AT NEXT WEEK. *TR

NHTSA ODI #10474313

35,000 miles · Jul 21, 2012
Power Train

THE TRANSMISSION/GEARS GETS STUCK WHEN I WANT TO PUT IT IN REVERSE. THIS HAPPENED 5 TIMES IN THE LAST 3 MONTHS. I BROUGHT THE CAR AND COMPLAINED TO THE DEALER AND THEY SAID IT COULD BE A BRAKE LIGHT ISSUE AND COULD NOT FIX IT UNLESS THEY SEE THE PROBLEM WHEN IT HAPPENS. THIS PROBLEM OCCURS RANDOMLY. IT HAPPENED AGAIN LAST WEE…

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THE TRANSMISSION/GEARS GETS STUCK WHEN I WANT TO PUT IT IN REVERSE. THIS HAPPENED 5 TIMES IN THE LAST 3 MONTHS. I BROUGHT THE CAR AND COMPLAINED TO THE DEALER AND THEY SAID IT COULD BE A BRAKE LIGHT ISSUE AND COULD NOT FIX IT UNLESS THEY SEE THE PROBLEM WHEN IT HAPPENS. THIS PROBLEM OCCURS RANDOMLY. IT HAPPENED AGAIN LAST WEEK SO I SCHEDULED TO BRING IT IN TO THE DEALER THIS WEEK. *TR

NHTSA ODI #10466849

Mileage unknown · Nov 7, 2011
Electronic Stability Control (esc)Power Train

TODAY I WAS OUT IN MY 2011 HYUNDAI TUCSON. TWO OF THE LIGHTS CAME ON THE DASH, ONE IS FOR TRACTION CONTROL AND THE OTHER HAD TO DO WITH HILLS(SORRY MY CAR IS AT THE DEALER AND I DON'T HAVE THE BOOK TO TELL YOU THE EXACT LIGHT DESCRIPTION; ONE IS ORANGE WITH A VEHICLE AND LITTLE SKID MARKS AFTER IT THE OTHER IS RED WITH A VEHICL…

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TODAY I WAS OUT IN MY 2011 HYUNDAI TUCSON. TWO OF THE LIGHTS CAME ON THE DASH, ONE IS FOR TRACTION CONTROL AND THE OTHER HAD TO DO WITH HILLS(SORRY MY CAR IS AT THE DEALER AND I DON'T HAVE THE BOOK TO TELL YOU THE EXACT LIGHT DESCRIPTION; ONE IS ORANGE WITH A VEHICLE AND LITTLE SKID MARKS AFTER IT THE OTHER IS RED WITH A VEHICLE GOING DOWN A STEEP HILL). I WENT TO STOP AT A STORE AND MY CAR WOULD NOT GO INTO PARK FROM DRIVE, THE FARTHEST I COULD GET IT WAS IN NEUTRAL. AFTER MESSING WITH IT FOR 5 MINUTES I FINALLY GOT THE CAR INTO PARK. AFTER LEAVING THAT STORE I WENT TO GO TO ANOTHER AND HAD THE SAME ISSUE. I IMMEDIATELY CALLED THE DEALER FOR SERVICE AND TOOK MY VEHICLE THERE. I HAVE DONE SOME SEARCHING ONLINE AND SEE THAT THIS IS NOT A NEW ISSUE WITH TUCSONS AS PEOPLE WITH OLDER MODELS(2010 AND BACK) HAVE ALSO HAD THE SAME ISSUE AND SOME OF THEM REPORT IT'S DUE TO A BAD BRAKE SWITCH AND ONCE IT WAS REPLACED THEY DIDN'T HAVE THE PROBLEM AGAIN. MY CAR WAS PURCHASED IN FEB OF 2011 AND HAS APPROXIMATELY 6600 MILES. *TR

NHTSA ODI #10434810

Official recalls

5

23V651000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Sep 22, 2023

Hyundai Motor America (Hyundai) is recalling certain 2011-2015 Elantra, Genesis Coupe, Sonata Hybrid, 2012-2015 Accent, Azera, Veloster, 2013-2015 Elantra Coupe, Santa Fe, 2014-2015 Equus, 2010-2012 Veracruz, 2010-2013 Tucson, 2015 Tucson Fuel Cell, and 2013 Santa Fe Sport vehicles. The Anti-Lock Brake System (ABS) module may leak brake fluid internally and cause an electrical short, which can result in an engine compartment fire while parked or driving.

Consequence & remedy

Consequence: An engine compartment fire while parked or driving can increase the risk of injury.

Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will replace the ABS fuse, free of charge. Owner notification letters were mailed April 10, 2024 through October 11, 2024. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 251.

19V063000 · Engine And Engine Cooling:engine

Feb 5, 2019

Hyundai Motor America (Hyundai) is recalling certain 2011-2013 Tucson vehicles. The engine oil pan may leak and, if not addressed, the loss of oil may result in engine damage.

Consequence & remedy

Consequence: A damaged engine can increase the risk of a fire or it can cause an engine stall, increasing the risk of a crash.

Remedy: Hyundai has notified owners, and dealers will inspect for an oil pan leak, replacing it if necessary, and install an updated oil pressure switch, free of charge. The recall began August 19, 2019. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 181.

16V057000 · Power Train:automatic Transmission:cooling Unit And Lines

Jan 28, 2016

Hyundai Motor America (Hyundai) is recalling certain model year 2011 Hyundai Tucson vehicles manufactured July 22, 2010, to October 31, 2010. The affected vehicles have a transmission fluid cooler hose that may have been improperly manufactured, resulting in a transmission fluid leak.

Consequence & remedy

Consequence: If enough transmission fluid leaks out, the transmission may not function properly and the vehicle may stop moving, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the transmission fluid cooler hose, free of charge. The recall is expected to begin March 25, 2016. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 139.

14V245000 · Air Bags

May 13, 2014

Hyundai Motor Company (Hyundai) is recalling certain model year 2011-2014 Hyundai Tucson vehicles manufactured January 3, 2011, through December 23, 2013. In the affected vehicles, the air bag assembly installed in the steering wheel may come loose from its mounting.

Consequence & remedy

Consequence: An air bag assembly that is not properly mounted may result in an increased risk of injury to the driver in the event of a crash.

Remedy: Hyundai will notify owners, and dealers will inspect and tighten the bolts that secure the driver's air bag assembly, free of charge. The recall began on May 9, 2014. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 118.

13V113000 · Exterior Lighting:brake Lights:switch

Apr 1, 2013

Hyundai Motor Company (Hyundai) is recalling certain model year 2006-2009 Accent, model year 2007-2011 Azera, Sonata and Sante Fe,2006-2011 Tucson, 2009-2011 Elantra Touring, 2007-2010 Elantra, 2008-2011 Veracruz, 2009-2011 Genesis, 2010-2011 Genesis Coupe, 2007-2008 Entourage, and 2006-2008 Tiburon vehicles. Originally, in April 2013, Hyundai recalled 1,059,824 model year 2007-2009 Accent and Tucson, model year 2007-2010 Elantra, model year 2007-2011 Santa Fe, model year 2008-2009 Veracruz, model year 2010-2011 Genesis Coupe, and model year 2011 Sonata vehicles. In September 2013, Hyundai informed the agency that it was adding more vehicles to this campaign, representing an additional 652,512 units. The total number of vehicles being recalled is now 1,712,336. In the affected vehicles, the stop lamp switch may malfunction. A malfunctioning stop lamp switch may cause the brake lights to not illuminate when the brake pedal is depressed or may cause an inability to deactivate the cruise control by depressing the brake pedal. Additionally, a malfunctioning stop lamp switch may also result in intermittent operation of the push-button start feature, affect the operation of the brake transmission shift interlock feature, preventing the shifter from being moved out of the PARK position and cause the Electronic Stability Control (ESC) malfunction light to illuminate.

Consequence & remedy

Consequence: Failure to illuminate the stop lamps during braking or inability to disengage the cruise control could increase the risk of a crash. Additionally, when the ignition is in the 'ON' position, the transmission shifter may be able to be moved out of Park without first applying the brake. This may lead to unintentional movement of the car which may increase the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the stop lamp switch, free of charge. The safety recall began on April 22, 2013. Owners may contact Hyundai at 1-800-633-5151. Hyundai's recall campaign number is 110.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

AQ23002 · Hyundai And Kia Abs Module Fires

Opened Nov 17, 2023 · No close date supplied

Status: open (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

DP22003 · Loss Of Motive Power

Opened Sep 12, 2022 · Closed Dec 12, 2023

Status: closed (inferred from source dates) · Engine

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.

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