Own a 2023 Hyundai Santa Fe Hybrid and have experienced the following issues over the past year and a half. Beginning after maybe 40,000 miles we pulled out onto a roadway and the engine immediately lost power and started flashing a glaring red warning that the hybrid system was failing and to pull over. We luckily were able to and turned the car off and waited. I tried to turn it on and it came back to life as if there was never an issue? We drove off. it left no warning code or did not update my Bluelink App. I took it to the dealership and they could not find any issues. Fast forward another 5 or 6 months and it happens again. Take it to the dealer and they keep it a week to go over it but still nothing. Within a week of getting it back it happens again and this time I am videoing it happening to me. Back to the dealer and provide the video because again the car did not log the event nor did it update my app. They hold it again for a week and try different things. They still cannot figure it out and I get it back.... it happens again.... This time the dealership was able to come up with an answer and that the oil level was too high. I got the car back and it seemed to work. Probably now 6 months go by and then this week I drive over to Jacksonville (5 hr drive) and visit. Again the car scares us on the highway and I have to pull over. Havea friend meet us with tools and we jack up the car and let out enough engine oil to insure we can read between the two marks on the dipstick. We drive off but the engine keeps hestitating and we almost make it back before it completly shuts down. We tow it to the Dealer in Jacksonville. They call the next morning like they can't find anything wrong! I explain everything and remind I don't tow cars for fun - something is wrong with the car and it is leaving us vulnerable and worst is it is not leaving any codes. Not sure but I have lost faith in Hyundai

Source: NHTSA complaint ODI #11719697 · view all complaints for this vehicle at nhtsa.gov

One two separate occasions while driving the car has lost the ability to accelerate. There is no acceleration power even when completely flooring the gas pedal. The dash displays a red circle warming that states "Check Hybrid system. Stop Safely". I have had to coast to the side of the road and then the car shuts off. It has taken several minutes before it can start again, and then displays a warning "Park with engine On to charge battery" before being able to shift the car into drive. I immediately took the vehicle to the dealership at which I had purchased the car. They have run a diagnostic on it and did not find any error codes stored in the computer. I picked up the vehicle from them and immediately upon pulling out of their lot it happened again. After losing power, coasting to the side of the road, and waiting for the engine to be able to restart I took it immediately back to the dealership. They have had my car for 5 weeks and cannot diagnose the problem or offer any recommendations for repairs.

Source: NHTSA complaint ODI #11706383 · view all complaints for this vehicle at nhtsa.gov

The contact owned a 2023 Hyundai Santa Fe. The contact stated that his partner was driving at 50 MPH, a light ahead had just turned red, with two vehicles stopped just a couple of feet ahead of her, the contact stated that his partner had proceeded to frantically attempt to brake, however, the vehicle did not brake in time, and the automatic braking assist did not initiate. The complete front end of the vehicle was destroyed, as the vehicle crashed into the vehicle ahead. There was no property damage. The vehicle came to a stop after the crash. The driver's side air bags were deployed, however, the contact emphasized that it appeared the air bag had not fully deployed. The vehicle was towed to a lot. No warning lights had illuminated. A police report was filed. The vehicle was destroyed. The contact partner was injured, and she was seated in the driver's seat, and a single civilian seated in the driver's seat of the vehicle that was hit from behind was injured. The contact stated that his partner suffered injuries to her chest, and the other individual suffered injuries to the neck. Medical treatment was needed for both individuals. The local dealer was contacted however the vehicle was not diagnosed, as the vehicle was a total loss, and the manufacturer was not notified of the failure. The approximate failure mileage was 23,824.

Source: NHTSA complaint ODI #11633727 · view all complaints for this vehicle at nhtsa.gov

While driving the blind spot safety system, driver attention warning system, and lane following system malfunction at the same time, and the vehicle loses power steering. The first time this occured was in the parking lot of an elementary school in April 2024. I was driving less than 2mph and the vehicle had less than 8,000 miles on it. The dealer said they would be unable to diagnose unless they witnessed the errors. The second time it occured was in May 2024 while driving on the interstate at around 75mph. The vehicle was driven directly to the dealership who kept it for four weeks. They said the connections to the ECU were severely corroded, sanded them down, and added a water protectant. The third time it occured was a month later. The dealership has had the vehicle for two weeks with no diagnosis. Losing power steering suddenly while driving is incredibly dangerous, especially in a vehicle of this size and weight. It is difficult to control the vehicle without power steering, and in all cases there have been other vehicles/people in the area who could have been injured.

Source: NHTSA complaint ODI #11601031 · view all complaints for this vehicle at nhtsa.gov

I am submitting this formal safety complaint regarding a structural defect in my 2023 Hyundai Santa Fe Hybrid that I believe poses a safety concern and warrants federal investigation under the National Traffic and Motor Vehicle Safety Act (49 U.S.C. § 30101 et seq.). The vehicle exhibits a persistent and recurring structural creak originating from the pinch weld area adjacent to the hybrid battery storage compartment — specifically at a metal-on-metal contact point above the rear driver-side wheel well. The noise presents most prominently at low speeds over uneven surfaces, driveway transitions, and speed bumps. The root cause, as identified by service documentation and owner community reports, is a manufacturing defect in the pinch weld construction where two metal body components make contact due to insufficient clearance tolerances. This affects the structural integrity of the body-in-white in proximity to the hybrid high-voltage battery system. III. SAFETY SIGNIFICANCE I am reporting this as a safety concern for the following reasons: •The defect involves structural body components adjacent to the high-voltage hybrid battery storage compartment. Any degradation of body structure in this area presents a potential risk of battery exposure, puncture, or damage in collision scenarios; •The metal-on-metal contact at the pinch weld constitutes an ongoing structural stress point that may accelerate fatigue and cracking of load-bearing body components over time; •The defect is present across a statistically significant number of 2023 Santa Fe Hybrid units based on online owner community documentation, suggesting a manufacturing pattern rather than an isolated anomaly; •Multiple authorized Hyundai service centers have been unable to provide a permanent repair, indicating the defect is systemic and not addressable through routine service procedures; •The proximity of the defect to hybrid drivetrain components warrants evaluation for potential regulatory compliance

Source: NHTSA complaint ODI #11741754 · view all complaints for this vehicle at nhtsa.gov