2011 Hyundai Santa Fe: Complaints, Recalls & Known Issues

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.

The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.

During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Hyundai Sonata and Santa Fe vehicles equipped with Theta II and Lambda II engines (approximately 1.3 million vehicles). ODI also reviewed field data of other Hyundai vehicles equipped with Theta II, Gamma, Nu and Lambda engines (approximately 4.8 million). As a result of this PE, Hyundai has issued NHTSA Recalls 20V-746 and 21V-727 to address potential engine failures and fires in certain Hyundai vehicles equipped with various engine types. Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov. In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure rewlated recalls mentioned above and conducted previously. See the EA21-003 Opening Resume available at NHTSA.gov for more information. Also available in the downloadable version of this resume is a list of the reference numbers for the 302 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021. Note that the Manufacturer reports cited above are customer complaints received through March 2019.

In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter dated July 24, 2018, CAS requested that MY 2010-2015 Kia Soul vehicles be added to the petition. CAS stated that there is a higher number of complaints to NHTSA regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened Recall Queries (RQ17-003 and RQ17-004) on all Kia and Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires.The queries cover most of the petition subject Optima, Sorento, Sonata, and Santa Fe vehicles but not any of the subject Soul vehicles.On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent Information Request letters to Kia and Hyundai (September and October 2018) requesting information on all engine and non-engine related fires in the petition vehicles.ODI performed extensive analysis on the information obtained from Kia and Hyundai. During the DP18-003 analysis, Kia and Hyundai each initiated three additional safety recalls related to engine compartment fires on certain petitioned and non-petitioned vehicles (nearly 740,000 total vehicles: Recalls 18V-907, 18V-934, 19V-101, 19V-063, 19V-120, and 19V-204). Based on ODI?s review of the applicable materials, including responses to Information Requests sent to multiple manufacturers, Vehicle Owner Questionnaires (VOQ), and Early Warning Data, NHTSA decided to grant the petition.The CAS petition was granted on March 29, 2019. Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) have been opened to assess the scope, frequency, and potential safety-related consequences of alleged defects relating to non-collision vehicle fires in the 2011-2014 Kia Optima and Sorento, 2011-2014 Hyundai Sonata and Santa Fe, and 2010-2015 Kia Soul.Attached is a list of the reference numbers for the 404 VOQs cited above.

The Office of Defects Investigation (ODI) opened PE12-029 based on one complaint alleging that a fastener became loose in the steering shaft of a model year (MY) 2011 Hyundai Santa Fe vehicle and related Early Warning Reporting field report data.In it's response to ODI's information request letter for PE12-029, Hyundai identified a total of four incidents of steering shaft universal joint failure in early production MY 2011 Santa Fe vehicles, including the incidents that had been identified by ODI. Two of the failures occurred at low mileage early in 2011, shortly after vehicle sale, leading to Hyundai's initial investigation.Hyundai attributed the failures to operator error at the vehicle assembly plant in failing to fully assemble the universal joint to the steering column shaft before tightening the universal pinch bolt.The company inspected 680 vehicles at the assembly plant as part of its initial investigation and found no additional indications of improper steering shaft assembly. Hyundai implemented changes in the assembly process to ensure proper steering shaft assembly, including the use of a go/no go Gap Gauge to ensure that the universal joint knuckle is fully assembled to the steering column shaft before being fastened.Hyundai believes that the improper assembly affected only a few vehicles and that joints that were not properly assembled should have already failed and the likelihood of additional failures is remote.None of the failures involved vehicles produced after the Gap Gauge implementation on April 27, 2011 and no additional failures have been reported since October 2012.Hyundai will notify ODI if any additional failures are reported to the company through the end of 2013.A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will take further action if warranted by the circumstances.