What 191 owners told NHTSA about the 2019 Hyundai Santa Fe Hybrid Hev

COMPLAINT SUMMARY: [XXX] / ENGINE THERMAL FIRE RISK / WARRANTY DECEPTION My 2019 Hyundai Santa Fe (2.4L GDI Engine) is experiencing severe powertrain degradation under the known Theta II engine defect class-action framework. On November 7, 2025, the vehicle logged a Permanent Diagnostic Trouble Code (DTC) P1326 via an independent scan, indicating catastrophic internal rod bearing wear. On XXX, the vehicle was brought to Hyundai of Milledgeville for safety recall verification. Instead of executing the mandatory corporate-directed Bearing Clearance Test (BCT) to replace the failing engine block, the service department committed technical campaign malpractice. The technician forced the 9C2 ECU Software Update directly over the locked mechanical fault to suppress the dashboard warning lights and alter the vehicle's ROM ID parameter limits. When caught via a photograph of their active GDS diagnostic tablet showing 7 historical system faults, the service manager provided a truncated printed report hiding Page 1 and omitting the critical P1326 powertrain code count to evade a warranty engine replacement. Due to these unmitigated delays, the vehicle has suffered severe consequential safety damage. The advanced engine degradation and oil consumption have flooded the exhaust system, melting the catalytic converter substrate and triggering a new DTC P042000 (Catalyst Efficiency) fault immediately after the dealer visit. The extreme engine vibrations have also damaged the transmission's torque converter clutch (DTC P074100). The dealership refused a service loaner and knowingly sent a disabled consumer and an elderly passenger away in an active, failing vehicle that presents a sudden stall-on-highway hazard and a severe thermal exhaust fire risk under extreme summer heat conditions. Hyundai Motor America Corporate has failed to provide emergency towing or alternative mobility accommodations despite a registered corporate case file. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11749805

My 2019 Hyundai Santa Fe 2.4L (VIN: [XXX]) is experiencing a severe safety defect involving rapid engine oil starvation. The vehicle recently failed an official oil consumption test conducted by Fred Beans Hyundai of Abington, where it was documented that the engine consumed 1 quart of oil in just 881 miles (PA Request #XXX). This vehicle is equipped with the Theta II engine, which currently has active warranty extensions (TXXC and TXXI) specifically covering connecting rod bearing failure. Despite the documented severe oil loss—which is the primary known cause of connecting rod bearing wear and sudden engine seizure—Hyundai Corporate (Case #XXX) is refusing to evaluate the vehicle under these warranties. They have improperly classified my claim as a denied "goodwill" request and are refusing to perform a connecting rod bearing clearance test to determine if the bearings have been damaged by this starvation. Because Hyundai refuses to perform the required diagnostic safety protocols, the vehicle must be driven in an oil-starved condition. This poses an imminent and severe safety risk of sudden engine seizure, stalling, and complete loss of motive power at highway speeds without warning, which could result in a catastrophic crash. The manufacturer is ignoring their own failure thresholds and putting driver safety at risk. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11742308

On March 04, 2026, I took my 2019 Hyundai Santa Fe to the local dealer for oil change service. As part of that service visit, they performed Hyundai recall 9C1 which was supposed to lower tailpipe emissions. The next morning, and ever since, my vehicle ran differently. The engine had several 1000rpm surges and was sluggish at other times. This behavior has continued. Particularly when I first start out in the morning and the engine is cold. Never after the engine is warmed up. A visit to the Hyundai forum shows a growing list of other Hyundai owners who are experiencing the same issues. This recall is defective and should be corrected.

NHTSA ODI 11742383

In December 2025, a Hyundai dealer performed Service Campaign 9C2 (TSB 25-01-087H), an ECU software update for the 2.4L GDI Theta II engine, during a routine annual NY state emissions inspection. Immediately following this update, the vehicle began exhibiting an RPM flare of approximately 1,200-1,500 RPM during upshifting under light acceleration. This behavior did not exist prior to the update. The condition occurs when ambient temperature is above 50°F and the vehicle has been parked 2+ hours after a prior drive. No warning lamps or fault codes have been present at any point. The issue has been confirmed across four dealer visits at two Hyundai dealerships over five months. Attempted remedies included transmission ECU updates and adaptive resets — none resolved the condition. On the fourth visit, the technician personally experienced the issue and identified reinstalling the pre-update ECU calibration as the likely fix, but stated the prior software version was unavailable. The repair order was nonetheless closed as "vehicle operating as designed." The case has been escalated to Hyundai Motor America National Consumer Affairs and forwarded to Hyundai engineering with no resolution to date. Multiple other 2019-2020 Santa Fe owners report identical post-9C2 symptoms on public forums, indicating a pattern associated with this campaign's ECU calibration. The unexpected RPM surge and erratic shifting during acceleration creates an unpredictable driving experience that could cause hesitation in traffic situations requiring smooth acceleration.

NHTSA ODI 11741031

Vehicle Information: 2019 Hyundai Santa Fe Mileage at failure: approximately 109,000 miles Manufacturer: Hyundai Motor Company The vehicle experienced a complete failure of the automatic transmission system. The failed component is available for inspection upon request. At approximately 98,000 miles, the vehicle’s check engine light illuminated. I brought the vehicle to an authorized Hyundai dealership for diagnosis while it was still within the 100,000-mile powertrain warranty period. The dealership inspected the vehicle and advised that no issue was found, and no repairs were performed at that time. Approximately 11,000 miles later, the vehicle experienced severe transmission problems, which progressed to complete transmission failure at approximately 109,000 miles. Safety Risk: The transmission failure resulted in a sudden loss of power and reduced vehicle operability while driving. This condition presents a potential safety risk to the driver and surrounding traffic, particularly during normal roadway and highway use. Prior Inspection / Diagnosis: The issue was not identified or reproduced during the dealership inspection at approximately 98,000 miles when the check engine light was present. Other Inspections: The vehicle was inspected by a Hyundai dealership at approximately 98,000 miles. No inspection by police, insurance representatives, or manufacturer engineering personnel has occurred since the transmission failure. Warning Signs: Check engine light illuminated at approximately 98,000 miles Vehicle was taken to dealership for diagnosis at that time No specific transmission warning messages were displayed Dealership reported no issue found Maintenance History: The vehicle has been regularly maintained with oil changes performed approximately every 5,000 miles. Maintenance records are available for review upon request.

NHTSA ODI 11734899

we took it in to be looked at after it had a o2 sensor go bad I changed the sensor and checked fluids I noticed the oil was a touch low and it had metal on the dipstick. I took in to dealership for repair / replacement and Hyundai denied the claim. Even after I have video proof from the dealer technician saying there is metal and bearing material in the oil. I took it to another dealership and they found metal in the oil control valve and still denied it. We got the car back because we were not provided a loaner or a rental. I called back in with concern that the car had a weird burning smell and the car would die. Then it started sounding weird as well. Then called again Saturday because I checked oil and it had fuel smell in the oil. Now today it left my family stranded on the highway. I have th 100,000 mile ten year warranty and the car is only at 83480 miles now when this all started it was at 82000. I have expressed my concern of safety before it finally left my family vernable to be injured in the lane that it died in This afternoon. Many denied claims and now very dangerous situation that was preventable and could have cause fire or death. I brought to manufactures attention early to prevent a accident happening. I was denied all the way through the process .

NHTSA ODI 11730989

The contact owns a 2019 Hyundai Santa Fe. The contact stated that while driving approximately 45 MPH, the vehicle hesitated while accelerating with the accelerator pedal depressed and the RPM raised. The contact stated that the vehicle occasionally failed to start. No warning light was illuminated. Additionally, while driving at various speeds, the vehicle lost automotive power. The vehicle was taken to a local dealer, where it was diagnosed, and determined that there were metal shavings in the oil pan. Hyundai Eugene (89320 N Game Farm Rd, Eugene, OR 97408) was contacted; however, the failure was not identified. Upon further investigation, the Hyundai Blue Link App retrieved DTC associated with the Power Train EMS and Power Train TCU. The vehicle was not repaired due to the cost. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 87,000.

NHTSA ODI 11717593

Since December my car has been burning oil at a fast rate. My husband has already had to add an additional 4 quarts since my last service 3000 miles ago. I have read and heard from others with a Santa Fe that they are having to replace their engines because of this. They are under warranty. Unfortunately I am not. I’ve already dealt with a white paint issue with Hyundai. I called couple weeks ago and was told someone would email me and they have not. I’m not sure where to turn now.

NHTSA ODI 11716394

Complaint: Safety Defect - Engine Failure Risk (Stalling/Fire) My 2019 Hyundai Santa Fe has the defective Theta II 2.0L Turbo engine (G4KH), subject of class action In re: Hyundai and Kia Engine Litigation and multiple TSBs. The engine has a known manufacturing defect causing premature connecting rod bearing failure, leading to catastrophic engine seizure. SAFETY CONSEQUENCE: This defect presents a clear, unreasonable safety risk: Sudden Stalling: Engine can seize without warning while driving, causing loss of propulsion and power steering/brakes, leading to a crash. Engine Fire: Failed engines can leak oil onto hot components, causing fires. MANUFACTURER'S INADEQUATE REMEDY: Hyundai's "Knock Sensor Detection System" software update (Campaign 966) only attempts to detect failure moments before it happens. It does NOT fix the underlying mechanical defect. The engine remains a ticking time bomb. PERSONAL EXPERIENCE: My vehicle has suffered multiple related failures (turbocharger, fuel injectors) costing over $5,700, confirming the powertrain's deterioration. I fear driving it, especially with my teenage daughter. The defect is well-known, yet Hyundai's settlements fail to protect subsequent owners like myself, leaving unsafe vehicles on the road. REQUEST: I urge NHTSA to investigate the ongoing safety risk these engines pose to all owners, compel Hyundai to issue a true safety recall for a permanent repair (e.g., engine long-block replacement), and mandate clear disclosure of this defect to all used car buyers.

NHTSA ODI 11712497

I was driving home Friday August 29th 2025 around 10:30 am on I-70 W when I began to have trouble accelerating my vehicle. There were vehicles trailing closely behind me so I increased pressure on the gas pedal. I would feel my car forcibly trying to compensate and the RPMs on the vehicle increased significantly. The check engine light then illuminated and the car stedily beagan to decelerate although RPMS were increasing and the force on the gas pedal was at its maximum. I could no longer get past 30 MPH. The cars behind me had to quickly change lanes behind me to avoid rear end collision and I finally pulled over to the shoulder of the highway but it was a very narrow shoulder so my safety and the safety of those driving around were compromised because they could have easily resulted in a high speed rear-end collision that could have been fatal and the location of my car on the shoulder was not safe and I could have been side-swipped waiting for a friend to come get me and for me to move my car off hat narrow shoulder. I was frantic and very emotionally distressed by this incident because all the maintenance on the car was up to date and there was no check engine light on in the car prior to this incident. The unexpected and decelleration and inability to compensate on the highway was very unsafe. I have taken my car to the delearship and they have yet to address my engine issues or the safety concerns. The rep actually laughed while I was recounting the events. I also called hagerstown police department to have a police officer come out to the breakdown site because I did not feel safe but my frined arrived before the police.

NHTSA ODI 11685129

Vehicle is shuddering/jerking upon acceleration due to a defect in the 8 speed automatic transmission. This condition was reproduced by Hyundai of Plymouth, MA and documented on the repair order. Dealer states that a new transmission is required to fix this problem. Safety is at risk due to shuddering upon acceleration which causes hesitation in acceleration. My Hyundai Santa Fe is available for inspection. There should be a recall on this vehicle.

NHTSA ODI 11656387

When accelerating the transmission slips. My mechanic said Hyundai has a memo saying they are making a new torque converter due to these problems, and I will need a new torque converter. The torque converter is on backorder and according to my mechanic, will not be available for many months; thus indicating there are many other folks with the same problem. This is very dangerous when accelerating, as the speed drops off due to the slippage, and can put me in a dangerous position if I need to accelerate to avoid a potential situation. It has also presented issues from a dead stop, pulling out into traffic, where the slippage puts me at risk. This has been going on for quite some time, and my mechanic has been doing what Hyundai memos instuct.

NHTSA ODI 11649788

The contact owns a 2019 Hyundai Santa Fe. The contact stated that while driving at various speeds, the vehicle lost motive power while depressing the accelerator pedal, with the check engine warning light illuminated. The vehicle was taken to a dealer and the turbo was replaced. The contact stated that months later, the vehicle hesitated and jerked while depressing the accelerator pedal with the check engine warning light illuminated. The vehicle was taken back to the dealer where a part on the transmission was replaced; however, the failure returned, and the check engine warning light illuminated. The vehicle was taken back to the dealer and the contact was informed that the transmission needed to be replaced. The contact took the vehicle to an independent mechanic and had the transmission replaced. The contact stated that months later, the vehicle began to sputter with an abnormal knocking sound coming from the vehicle. The check engine warning light returned, and the vehicle was taken to the nearest dealer. The vehicle was diagnosed with engine failure. The vehicle was not repaired and remained with the dealer. The manufacturer was not notified of the failure. The failure mileage was approximately 87,000.

NHTSA ODI 11640859

We have had our vehicle for over 2 years with routine maintenance. On 1/25/26 We were driving home and oil light came on then check engine light. The oil pressure the issue.

NHTSA ODI 11638681

Transmission: yes, available upon inspection I own a 2019 Hyundai Santa Fe. I have brought it in for repairs on the transmission a couple of times. The check engine light has come on but the computer was not displaying the problem. I am aware that this is not uncommon for the year, make, and model. Recently, I was driving my car on a high-speed highway when the transmission went out. While suppressing the gas, the transmission slipped and would not accelerate. As cars were passing me on either side, my car decelerated and cars behind me came close to rear-ending me. Again, this was at high speeds and put my safety in jeopardy. I was finally able to find a gap in the cars and able to get to the shoulder but not after several minutes of unsafe conditions. After this incident, I brought it back to the service center and the computer analysis did display that it is an internal transmission problem. The service center has inspected the transmission. Yes, the warning lamps were displaying, first about 8 months prior. As stated previously, the actual problem was not displaying. Attached document is previous work done for transmission due to incorrect computer diagnostics.

NHTSA ODI 11631403

Upon going for an oil change at Express Lube in Newton , NJ I was advised that there are multiple widespread & ongoing problems with a crack that forms in the oil pan next to the drain/fill plug. My vehicle was diagnosed with that very problem. I believe a a recall to should be done by Hyundai to replace these oil pans. Thank you

NHTSA ODI 11629483

My car just stalls at a stop ligth , no check engine light, no warning, and takes several attempts to start. It happened 3 times in two weeks one of those time while in the highway. One a the stop ligth and one driving in the neighborhood.

NHTSA ODI 11613909

Front CV Joint inner axle boot losing grease due to manufacture insufficient torque or poor quality of the clamp material.

NHTSA ODI 11583945

For the past month my car has been stalling in traffic. The car stalls and then turns back on a few seconds later. It also stalls when I am accelerating after stopping for a red light. This situation is very dangerous and it means that I cannot drive my car expecting to be safe at all. It seems like the motor and the transmission are involved which makes the stalling very dangerous as those are major systems.

NHTSA ODI 11578525

The contact owns a 2019 Hyundai Santa Fe. The contact stated that on various occasions while driving at various speeds with the automatic START/STOP function activated, the vehicle started losing motive power while the brake pedal was depressed. The contact stated that the failure recurred while driving from a complete stop. The vehicle was able to restart. No warning light was illuminated. The vehicle was taken to a local dealer where it was diagnosed that the valve cover gasket needed to be replaced. The vehicle was not repaired. Additionally, the contact stated that the All-Wheel Drive (AWD) warning light was intermittently illuminated. The manufacturer was not made aware of the failure. The failure mileage was 75,500.

NHTSA ODI 11517467

The contact owns a 2019 Hyundai Santa Fe. The contact stated while driving from a stop signal, the vehicle experienced a delay while accelerating. The contact stated that the vehicle was jerking without warning. The contact stated that on another occasion while driving 60 MPH, the vehicle inadvertently made a sudden stop without warning. The vehicle was taken to the dealer; however, the mechanic was unable to determine the cause of the failure. The manufacturer was not contacted. The failure mileage was 34,000.

NHTSA ODI 11509557

Was driving my 2019 Hyundai Santa Fe and it completely shut off when I was stopped at a red light. Super scary! I could not get the vehicle to start again and had to call police to help. Had my hazard lights on but still felt very unsafe because there was traffic that had to go around my vehicle. Tow guy was able to get it to start again but said the transmission felt jerky. The vehicle was towed back to my home. Then the next day the vehicle was able to start and seemed fine. I had a friend drive it to the dealership while I followed behind in another vehicle. Half way there, it did the exact same thing. Was stopped at a red light and it turned off. The reason felt like a hard shift to the transmission. The engine would start but it would not shift to drive. It had to be pushed out of traffic. A few people stopped their vehicles to help push. After it was pushed to a safe spot, I had it towed to the nearest Hyundai dealership. The dealership service tech thought it just needed a new starter. He installed the starter and some update software and claimed it was fixed. Picked up the car, drove it home and it seemed fine. The next day I needed to use this car to drive my three children to school (one of my kids has special needs). I felt the transmission jerking half way there and by the time we (thankfully) made it to the school parking lot, it did a hard shift and died. That could have been very scary and unsafe if we were stuck in traffic and it died! I had it towed back to the dealership. This time around the service tech said it needs a new transmission. It’s a 2019 vehicle with 40,000 miles. It shouldn’t need a new transmission. I don’t feel safe driving this vehicle, especially with my three children!

NHTSA ODI 11503082

2019 Hyundai Santa fe first owner after each use of the Auto Stop/ Start feature is guaranteed that in 24-48 hrs the car will stall at stop lights and take anywhere from 15-20 min to restart. The power to the electronics continues but the engine can't restart from the stop. It appears as of the feature takes the power from the alternator, starter and battery and drains it until the car can be restarted. Once it starts it drives well until the system is engaged again. I have chosen to not use the system and the car has not stall however once the use of the Auto/ Start Stop system is engaged for a day or two it will stall the vehicle from a stop mostly at stop lights after so much time on standby mode while using the Auto Start / Stop system. Dealer can not recreate the issue.

NHTSA ODI 11490525

WE WERE SITTING AT RED LIGHT IN A BUSY INTERSECTION AT NIGHT AND THE VEHICLE STARTED HESITATING AND CUT OFF. WE TRIED PRESSING THE AUTOMATIC START AND IT KEPT HESITATING AND EVERYTHING WENT BLACK ON THE INSTRUMENT PANEL.AFTER 3RD TIME IT STARTED AND WE WERE ABLE TO GET HOME. IT STARTED HAVING MORE HESITATION WHILE TO GO UP HILLS AND LOW SPEEDS. THE AUTOMATIC START /STOP ALSO STOPPED WORKING IN THE VEHICLE. I ALSO WAS HAVING TROUBLE WITH THE BLUE LINK SYSTEM, THEY WERE HAVING TO RESET IT EACH MONTH UNTIL THEY DECIDED TO MAKE A TICKET FOR REPAIR IN WHICH TOOK A MONTH OR SO IN ORDER FOR THE ENGINEERS TO SEE IF IT WAS DEFAULT ON THERE END. THEN THEY DECIDED TO SET ME UP FOR A APPOINTMENT TO HAVE IT LOOKED AT THROUGH HYUNDAI, WHICH NOW THEY SAW I HAVE TO HAVE WHOLE NEW HEAD RADIO HEAD UNIT WITH BLUE LINK AND ALSO A NEW TRANSMISSION. PURCHASED BRAND NEW AND IT HAS LOW MILEAGE AND NEED TRANSMISSION. I'M LOOSING FAITH IN HYUNDAI!

NHTSA ODI 11396372

THE CAR HAS SHIFTED A LITTLE ROUGH ABOUT A WEEK AFTER BUYING THE CAR AND HAS GOTTEN TO THE POINT IT LUNGES YOU FORWARD. IT SHIFTS SO ROUGH I HAD TO GO TO THE ER FOR PINCHING A NERVE IN MY NECK. *TR

NHTSA ODI 11326189