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2016 Hyundai Tucson

Owner reports · Recalls · Investigations

More warning signs than most Tucson years

Owner complaints for the 2016 Hyundai Tucson are substantially higher than the model-year median of 180.5.

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When problems were reported

Mileage at the reported incident

832 reports with mileage · 785 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.

  • Power Train. Review the 516 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 423 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 227 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

14 crash reports24 fire reports6 injury reports

Structure complaints

227 reports
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71,000 miles · Nov 5, 2020
Structure

THE MOTOR IN THE DOORS BLOW (ACCORDING TO THE INFORMATION I RECEIVED FROM HYUNDAI A COUPLE YEARS AGO.) WHEN THIS HAPPENS, THE PASSENGERS ARE LOCKED IN THE CAR WITHOUT ANY WAY OF BEING ABLE TO GET OUT. THE DOOR WILL NOT OPEN FROM THE INSIDE OR THE OUTSIDE OF THE CAR. THESE PARTS WERE REPLACED WHILE THE CAR WAS UNDER WARRANTY. THI…

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THE MOTOR IN THE DOORS BLOW (ACCORDING TO THE INFORMATION I RECEIVED FROM HYUNDAI A COUPLE YEARS AGO.) WHEN THIS HAPPENS, THE PASSENGERS ARE LOCKED IN THE CAR WITHOUT ANY WAY OF BEING ABLE TO GET OUT. THE DOOR WILL NOT OPEN FROM THE INSIDE OR THE OUTSIDE OF THE CAR. THESE PARTS WERE REPLACED WHILE THE CAR WAS UNDER WARRANTY. THIS HAS HAPPENED AGAIN WITH THE SAME VEHICLE AND NOW WILL NOT BE COVERED SINCE IT IS NO LONGER UNDER WARRANTY. THIS IS A SAFETY HAZARD THAT TRAPS THE PASSENGERS IN THE CAR.

NHTSA ODI #11373242

Mileage unknown · Nov 3, 2020
Structure

THE REAR PASSENGER DOORS LEFT AND RIGHT DO NOT OPEN. THE DOORS ARE UNLOCKED AND THEY BOTH WILL NOT OPEN. YOU HAVE TO PULL THE HANDLE MORE THAN 30 TIMES FOR THE DOORS TO OPEN. IT'S NOT SAFE AND MY CHILD HAS BEEN STUCK IN THE CAR WAITING FOR ME TO GET HER OUT.

NHTSA ODI #11372829

122,000 miles · Oct 26, 2020
Electrical SystemStructure

BACK PASSENGER DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE AND THE WINDOW WILL ONLY ROLL UP OR DOWN USING THE SWITCH ON THE DOOR AND NOT THE MASTER SWITCH ON THE DRIVER DOOR. PRESENTS A SAFETY HAZARD FOR ANY BACK SEAT PASSENGER. IT WAS WORKING ON MINUTE AND THEN COMPLETELY QUIT WITH THE WINDOWDOWN.

NHTSA ODI #11366437

Mileage unknown · Oct 23, 2020
Structure

I BOUGHT MY CAR IN 2017 WITH ROUGHLY 33000 MILES ON IT. IT NOW HAS ROUGHLY 89000 ON IT. I FIRST HAD PROBLEMS WITH THE DRIVER SIDE WINDOW NOT WORKING. BOUGHT A MOTOR HAD IT REPLACED. NOW MY DRIVERSIDE DOOR OPENS SOMETIMES, YOU HAVE TO PULL HANDLE 3 OR 4 TIMES TO OPEN IT. DRIVER SIDE REAR DOOR WON'T OPEN FROM INSIDE OR OUTSIDE AT …

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I BOUGHT MY CAR IN 2017 WITH ROUGHLY 33000 MILES ON IT. IT NOW HAS ROUGHLY 89000 ON IT. I FIRST HAD PROBLEMS WITH THE DRIVER SIDE WINDOW NOT WORKING. BOUGHT A MOTOR HAD IT REPLACED. NOW MY DRIVERSIDE DOOR OPENS SOMETIMES, YOU HAVE TO PULL HANDLE 3 OR 4 TIMES TO OPEN IT. DRIVER SIDE REAR DOOR WON'T OPEN FROM INSIDE OR OUTSIDE AT ALL. WHY IS THERE NO RECALL ON THIS?THIS IS A SAFETY ISSUE TO THE MAX! I AM 57AND CAN'T BE CLIMBING OVER SEATS OR CONSOLES TO GET OUT! I ALSO CAN'T AFFORD THESE KINDS OF REPAIRS. I AM PAYING 400 A MONTH FOR A DEATH TRAP! NO ONE CAN RIDE WITH ME BECAUSE THEY WOULDN'T BE ABLE TO GET OUT OF THE CAR UNLESS THEY CROSSED OVER SEATS! PLEASE HELP WITH THIS. I AM NOT THE ONLY ONE HAVING TROUBLE WITH THIS ISSUE EITHER.

NHTSA ODI #11365888

49,000 miles · Oct 16, 2020
Structure

MY PASSENGER DRIVERS SIDE DOOR WILL NOT OPEN OR UNLOCK. I TOOK TO THE HYUNDAI DEALER PRIME HYUNDAI IN PLYMOUTH ANDS WASN TOLD MY DOOR ACUATOR WAS BENT???????IF THE DOOR WAS HARDLY USEDN AND NOT IN AN ACCIDENT THAT MEANS THE PART WAS ALWAYS BENTBB. THE DEALER WANTS $460.00 TO REPLACE. I HAD PREVIOUS APPTS. TO HAVE REPAIRED AND CO…

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MY PASSENGER DRIVERS SIDE DOOR WILL NOT OPEN OR UNLOCK. I TOOK TO THE HYUNDAI DEALER PRIME HYUNDAI IN PLYMOUTH ANDS WASN TOLD MY DOOR ACUATOR WAS BENT???????IF THE DOOR WAS HARDLY USEDN AND NOT IN AN ACCIDENT THAT MEANS THE PART WAS ALWAYS BENTBB. THE DEALER WANTS $460.00 TO REPLACE. I HAD PREVIOUS APPTS. TO HAVE REPAIRED AND COULDN'T MAKE THEM. I AM NOT UNDER WARRANTY BY 14 DAYS.. I FEEL THIS IS A SAFETY ISSUE, AND WHY WASNT IT UNDER WARRANTY.

NHTSA ODI #11364631

45,000 miles · Oct 14, 2020
Structure

MY DRIVER SIDE REAR DOOR DOES NOT OPEN. I HAVE SEEN A HYUNDAI DEALER AND IT WAS NOT COVERED UNDER MY WARRANTY BY 2 WEEKS. (I DID HAVE AN APPOINTMENT IN SEPTEMBER BUT COULDN'T GET TO THE DEALER.)I HAVE NOT BEEN DRIVING THE. AT TO MUCH WITH THE COVID 19 DISEASE. THE DOOR HASN'T OPENED IN COUPLE OF MONTHS. I FEEL THIS IS A SAFETY I…

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MY DRIVER SIDE REAR DOOR DOES NOT OPEN. I HAVE SEEN A HYUNDAI DEALER AND IT WAS NOT COVERED UNDER MY WARRANTY BY 2 WEEKS. (I DID HAVE AN APPOINTMENT IN SEPTEMBER BUT COULDN'T GET TO THE DEALER.)I HAVE NOT BEEN DRIVING THE. AT TO MUCH WITH THE COVID 19 DISEASE. THE DOOR HASN'T OPENED IN COUPLE OF MONTHS. I FEEL THIS IS A SAFETY ISSUE AND SHOULD BE FIXED BY HYUNDAI. I HAVE READ OTHER PEOPLE'S SAME PROBLEM.

NHTSA ODI #11364338

67,000 miles · Oct 8, 2020
Structure

ACCORDING TO HYUNDAI (AND SEVERAL OTHERS IN VARIOUS ONLINE FORUMS), THERE IS A KNOWN DOOR LATCH ISSUE THAT AFFECTS 2015 AND NEWER HYUNDAI TUCSONS AND POSSIBLY OTHER HYUNDAI MODELS. OUR 2016 HYUNDAI TUCSON REAR DRIVER'S SIDE DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE AND THE FRONT DRIVER'S SIDE DOOR WILL ONLY OPEN FROM THE INS…

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ACCORDING TO HYUNDAI (AND SEVERAL OTHERS IN VARIOUS ONLINE FORUMS), THERE IS A KNOWN DOOR LATCH ISSUE THAT AFFECTS 2015 AND NEWER HYUNDAI TUCSONS AND POSSIBLY OTHER HYUNDAI MODELS. OUR 2016 HYUNDAI TUCSON REAR DRIVER'S SIDE DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE AND THE FRONT DRIVER'S SIDE DOOR WILL ONLY OPEN FROM THE INSIDE. THIS POSES A MAJOR SAFETY CONCERN DUE TO THE FACT THAT IF THE PASSENGER'S SIDE WAS TO BECOME DAMAGED OR BLOCKED, IT WOULD BE NEARLY IMPOSSIBLE TO 1. ESCAPE THE VEHICLE, OR 2. SAVE SOMEONE IN THE BACKSEAT DURING AN EMERGENCY- SPECIFICALLY CHILDREN IN CAR SEATS, PEOPLE WITH DISABILITIES OR ELDERLY WHO REQUIRE ASSISTANCE. IF THIS IS A KNOWN ISSUE, AND LATER AFFECTS THE PASSENGER'S SIDE, ONE COULD POTENTIALLY HAVE TO BREAK A WINDOW JUST TO EXIT THE VEHICLE. THIS ISSUE PUTS DRIVERS AND PASSENGERS IN IMMINENT DANGER, NOT TO MENTION THE STRESS, FRUSTRATION AND FEAR OF NOT BEING ABLE TO OPEN YOUR CAR DOOR TO REMOVE A CHILD FROM A CAR SEAT OR LOVED ONE INTO THEIR WHEEL CHAIR. THIS IS UNACCEPTABLE FOR ANY VEHICLE, ESPECIALLY ONE THAT IS ONLY 3.5 YEARS OLD. HYUNDAI'S UNWILLINGNESS TO REPAIR THIS PROBLEM FOR ANYTHING LESS THAN $1000 BECAUSE THE VEHICLE HAS TOO MANY MILES IS OUTRAGEOUS. THIS HAS NOTHING TO DO WITH MILEAGE- IT IS A SAFETY CONCERN NEEDING AN IMMEDIATE RECALL. BEING LOCKED/TRAPPED INSIDE A VEHICLE IS NEVER OKAY.

NHTSA ODI #11363320

65,000 miles · Sep 25, 2020
Electrical SystemStructure

THE RIGHT REAR DOOR OF THE VEHICLE WILL NOT OPEN FROM EITHER THE INSIDE OR OUTSIDE. IT WAS A SUDDEN FAILURE. WORKED WHEN WE STOPPED THE VEHICLE, DID NOT WORK WHEN WE RETURNED TO THE VEHICLE 15 MINUTES LATER. IT SOUNDS LIKE THE ELECTRIC LOCKS ARE TRYING TO WORK AND THE PHYSICAL BUTTON ON THE INSIDE IS SHOWING TO BE UNLOCKED, B…

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THE RIGHT REAR DOOR OF THE VEHICLE WILL NOT OPEN FROM EITHER THE INSIDE OR OUTSIDE. IT WAS A SUDDEN FAILURE. WORKED WHEN WE STOPPED THE VEHICLE, DID NOT WORK WHEN WE RETURNED TO THE VEHICLE 15 MINUTES LATER. IT SOUNDS LIKE THE ELECTRIC LOCKS ARE TRYING TO WORK AND THE PHYSICAL BUTTON ON THE INSIDE IS SHOWING TO BE UNLOCKED, BUT NEITHER THE INSIDE HANDLE OR OUTSIDE HANDLE WILL OPEN THE DOOR.

NHTSA ODI #11361180

Mileage unknown · Sep 24, 2020
Structure

MY DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE. BOTH MY BACK PASSENGER SIDE DOOR AND FRONT PASSENGER SIDE DOOR HAVE STOPPED OPENING. THIS IS A SAFETY HAZARD. ESPECIALLY WHEN YOU HAVE CHILDREN, I HAVE 2 KIDS UNDER 5 IN CAR SEATS AND IF I NEEDED TO GET THEM OUT IN AN EMERGENCY I WOULD NOT BE ABLE TO IN A TIMELY MANNER. I'VE SEEN…

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MY DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE. BOTH MY BACK PASSENGER SIDE DOOR AND FRONT PASSENGER SIDE DOOR HAVE STOPPED OPENING. THIS IS A SAFETY HAZARD. ESPECIALLY WHEN YOU HAVE CHILDREN, I HAVE 2 KIDS UNDER 5 IN CAR SEATS AND IF I NEEDED TO GET THEM OUT IN AN EMERGENCY I WOULD NOT BE ABLE TO IN A TIMELY MANNER. I'VE SEEN MULTIPLE REPORTS OF THIS SAME ISSUE, I SHOULD NOT HAVE TO PAY $1000 FOR MY DOOR TO OPEN.

NHTSA ODI #11360911

90,000 miles · Sep 23, 2020
Electrical SystemStructure

IT ALL STARTED OUT WITH THE DRIVER DOOR. THE PUSH BUTTON FELL OFF, THE DOOR WAS STILL ABLE TO OPEN BUT NOW THE WIRES ARE EXPOSED. THE CO-PILOT DOOR FAILED AT OPENING. YOU HAVE TO PULL IT THREE TIMES BEFORE IT OPENS. THEN THE CO-PILOT WINDOW STOPPED FUNCTIONING. WENT TO GO GET IT FIXED AND THEY SAID THE DOOR SHOULD BE FIXED AFTER…

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IT ALL STARTED OUT WITH THE DRIVER DOOR. THE PUSH BUTTON FELL OFF, THE DOOR WAS STILL ABLE TO OPEN BUT NOW THE WIRES ARE EXPOSED. THE CO-PILOT DOOR FAILED AT OPENING. YOU HAVE TO PULL IT THREE TIMES BEFORE IT OPENS. THEN THE CO-PILOT WINDOW STOPPED FUNCTIONING. WENT TO GO GET IT FIXED AND THEY SAID THE DOOR SHOULD BE FIXED AFTER REPLACING THE MOTOR. FALSE. DOOR STILL DOES NOT WORK. REAR PASSENGER DOOR DOES NOT OPEN FROM INSIDE OR OUT. COULD BE A RISK SINCE NOW ONLY ONE DOOR IN THE BACK IS OPERABLE. THE WINDOW FROM THE DRIVER DOOR STOPPED OPERATING. THAT IS NOW THREE OF 4 DOORS. WHAT IS IT GOING TO TAKE UNTIL THIS IS A RECALL? ALSO WHEN THE PASSENGER WINDOW GOT FIXED THEY SAID THE PLASTIC MOTOR WAS SLIGHTLY MELTED?! FIRE HAZARD.

NHTSA ODI #11360745

Official recalls

5

20V543000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Sep 4, 2020

Hyundai Motor America (Hyundai) recalled certain 2019-2021 Tucson vehicles on September 4, 2020. On December 30, 2020, Hyundai expanded the recall population, and added certain 2016-2018 Tucson vehicles. The Anti-lock Brake Hydraulic Electronic Control Unit (HECU) could corrode internally and cause an electrical short, possibly resulting in an engine compartment fire.

Consequence & remedy

Consequence: An engine compartment fire can increase the risk of injury or crash.

Remedy: Hyundai will notify owners, and dealers will replace the HECU fuse. For 2019-2021 model years, the Electronic Stability Control (ESC) software will also be updated. Recall repairs will be performed free of charge. Owners are advised to park outside and away from structures as a precaution until the recall repair is complete. The recall began November 2, 2020. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 195.

16V842000 · Electrical System:wiring; Trailer Hitches

Nov 21, 2016

Hyundai Motor America (Hyundai) is recalling certain model year 2016-2017 Tucson vehicles manufactured May 19, 2015, to November 14, 2016, and 2017 Santa Fe vehicles manufactured November 28, 2015, to November 14, 2016. The affected vehicles may be equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result, in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence & remedy

Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the affected accessory trailer hitch wiring harnesses, free of charge. The recall is expected to begin January 13, 2017. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 153.

Additional source detail variants (2)

Trailer Hitches

Hyundai Motor America (Hyundai) is recalling certain model year 2016-2017 Tucson vehicles manufactured May 19, 2015, to November 14, 2016, and 2017 Santa Fe vehicles manufactured November 28, 2015, to November 14, 2016. The affected vehicles may be equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result, in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the affected accessory trailer hitch wiring harnesses, free of charge. The recall is expected to begin January 13, 2017. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 153.

Electrical System:wiring

Hyundai Motor America (Hyundai) is recalling certain model year 2016-2017 Tucson vehicles manufactured May 19, 2015, to November 14, 2016, and 2017 Santa Fe vehicles manufactured November 28, 2015, to November 14, 2016. The affected vehicles may be equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result, in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the affected accessory trailer hitch wiring harnesses, free of charge. The recall is expected to begin January 13, 2017. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 153.

16V628000 · Electrical System:software; Power Train:automatic Transmission:control Module (tcm/pcm/tecm)

Aug 30, 2016

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 20, 2015 through May 31, 2016 and equipped with a 7-speed EcoShift Dual Clutch Transmission. Certain driving conditions and high temperatures may cause the vehicle to not move if the accelerator pedal is pressed and released repeatedly.

Consequence & remedy

Consequence: Inability to move the vehicle while in traffic may increase the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the Transmission Control Module software, free of charge. The recall is expected to begin on October 28, 2016. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 149.

Additional source detail variants (2)

Electrical System:software

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 20, 2015 through May 31, 2016 and equipped with a 7-speed EcoShift Dual Clutch Transmission. Certain driving conditions and high temperatures may cause the vehicle to not move if the accelerator pedal is pressed and released repeatedly.

Consequence: Inability to move the vehicle while in traffic may increase the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the Transmission Control Module software, free of charge. The recall is expected to begin on October 28, 2016. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 149.

Power Train:automatic Transmission:control Module (tcm/pcm/tecm)

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 20, 2015 through May 31, 2016 and equipped with a 7-speed EcoShift Dual Clutch Transmission. Certain driving conditions and high temperatures may cause the vehicle to not move if the accelerator pedal is pressed and released repeatedly.

Consequence: Inability to move the vehicle while in traffic may increase the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the Transmission Control Module software, free of charge. The recall is expected to begin on October 28, 2016. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 149.

16V348000 · Latches/locks/linkages:hood:latch

May 24, 2016

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 19, 2015 to March 14, 2016. In the affected vehicles, if the primary hood latch has been released, and the vehicle is driven, the secondary hood latch may not hold adequately secure the hood to prevent it from opening while the vehicle is in motion.

Consequence & remedy

Consequence: If the primary hood latch is inadvertently released and the secondary latch cannot secure the hood, the hood may unexpectedly open while driving, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the secondary hood latch, free of charge. The recall began on June 30, 2016. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 145.

16V147000 · Exterior Lighting:tail Lights

Mar 10, 2016

Hyundai Motor America (Hyundai) is recalling certain model year 2016 Hyundai Tucson vehicles manufactured May 26, 2015 to January 15, 2016 and equipped with an accessory trailer hitch harness either included with the accessory trailer hitch or sold as a service part. In the affected vehicles, when the vehicle's engine is running and the brake lights are illuminated, if the turn signal is activated, the trailer turn signal lights will either turn off or remain continuously illuminated (not flash). As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard Number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence & remedy

Consequence: Failure to illuminate the trailer's turn signal lights would prevent the communication of the driver's intent, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the tow hitch harness, free of charge. The recall began on May 2, 2016. Owners may contact Hyundai customer service at 1-855-371-9640. Hyundai's number for this recall is 142.

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

1

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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