2022 Hyundai Ioniq 5

Hyundai issued TSB 22-01-094H for my vehicle which is an update to the battery management system,, but after 4 attempts Hyundai dealerships have still not been able to complete the TSB. Hyundai corporate has also not helped after multiple cases. After many hours of research, I have determined that my vehicle's BMS software was updated to an intermittent version (version 700x) that does not support this TSB via automatic update, and the correct BMS Rom (version 540x) must be selected manually, which the dealerships are unwilling or unable to do.

On [XXX], I was driving my 2022 Hyundai Ioniq 5 SEL when all of a sudden the car started beeping and displaying a 12V battery voltage low. Stop safely message. I was traveling on [XXX] in the Las Vegas area and the car all of a sudden came shut off seconds later. This presented a very dangerous situation with other vehicles traveling at 65+ mph and the vehicle shutting off. I was able to use a portable power jump starting pack to at least get the car restarted and pulled off the side of the highway. Even after jump starting the vehicle, it would only stay running for a minute before shutting off again. The is the second time in 2 months that my car has lost power. The dealer, ABC Hyundai in Las Vegas did a ICCU recall and said that would solve the problems. The problem has not been resolved and I do not feel this is a safe vehicle to drive. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Hyundai of Fort Myers Repair Order Number [XXXX] Dear NHTSA Team, I am reaching out to formally report a significant safety concern involving our Hyundai Ioniq 5, which recently experienced an Integrated Charging Control Unit (ICCU) failure. This malfunction occurred despite our vehicle receiving all relevant software and hardware updates that Hyundai implemented to address this known issue. This experience has caused our family considerable distress and has raised serious doubts about the reliability of this model, as well as the adequacy of Hyundai’s current safety measures to prevent ICCU failure. While my wife and young daughter were in the car, the ICCU failure occurred suddenly, producing a loud pop that alarmed us all, particularly my daughter who was seated in the rear. She has since expressed fear about riding in the Ioniq 5, making it clear that this issue has impacted her sense of security in the car. Despite the updates Hyundai has issued, the failure occurred without warning, putting us in a vulnerable situation and highlighting that the current remedies may be insufficient to prevent this risk. The gravity of this problem is amplified by my wife’s critical health needs. She is currently on the waiting list for a kidney transplant, and our family requires a dependable vehicle to ensure she can be transported quickly and safely to her medical appointments and, when the time comes, to the hospital for her transplant. We cannot rely on the Ioniq 5 for these crucial needs given our recent experience with this unexpected breakdown. I am requesting that the NHTSA investigate this issue, as our experience suggests that Hyundai’s current measures to address ICCU failure may not adequately safeguard Ioniq 5 owners. A comprehensive review of this problem could be critical in ensuring the safety of other drivers and families who may be unknowingly exposed to the risk of sudden vehicle malfunctions. We hope that the NHTSA will consider further action

Today when I was driving down a canyon going 40 mph, the car started coasting and the accelerator was unresponsive. I couldn't keep the car from decreasing speed and regen braking wasn't working either. I don't know whether it's related, but this happened within seconds of me turning off daylight savings time in the menu. I coasted to a safe place to pull over (the brakes worked fine), but I could not get the accelerator to work after switching from drive to park to drive again. After turning the car off and then back on, the accelerator again worked like normal. After continuing driving, I turned daylight savings time on and off a few times, but nothing adverse happened.

At around 9pm, while charging my vehicle, I heard a loud boom and the power went out. It appears there was some sort of malfunction with the charger that has tripped/blown the circuit. I have not had an electrician come out yet, but after a quick google search it became apparent that others have experienced the same issue and I thought it was important to report. My charger is outside, not in a garage or enclosed space, so there was no fire that I am aware of.

While we were driving the Ioniq recently when it suddenly lost all power. We had a very brief warning on the dash that it was losing its power; we barely had enough time to pull onto a side street. It lost power so quickly we couldn't position the car properly and it stayed in the middle of the side street until the tow truck came and jumped the 12 volt battery enough to get the car into gear so it could drive up the tow truck ramp. The scary part was that we were only a block away from turning onto busy Highway 522 when it died. Had the car died on the highway we could have been stranded in a very unsafe position. The dealer later diagnosed the problem as a failed ICCU and 12-volt battery and replaced both. We had to rent a car for 3 days.

Car on 2 separate occasions once parked the other while in motion discharged unexpectedly and would not start. I was later notified by a contracted service station that the 12V battery is discharging and needs to be replaced or serviced by dealer. These events only started happening after a recent recall update was done to the vehicle for battery management. Warning signs on the vehicle said 12v voltage low stop safely.

After all the recalls and TBS that Hyundai has performed on this car to prevent any ICCU failures I still had the failure after all the updates. Last week after AC charging to 80% (7.6kw) the car thru an error code to check EV when starting up. It was only yellow so I attempted to drive it. Within 1/4 block the error code was flashing red and a warning was given to pull over and stop. Since I was only a block away I made it back home. The car had to be towed to the local dealer. Upon inspection they retrieved error code P1A9096 that said the ICCU failed. The ICCU fuse was also blown (open). This did not cause a safety issue this time but if I would have been on the road who knows. Also the replacement ICCU appears to be the same part number as removed? I do not believe Hyundai fully understands the issue and software updates have only corrected or is masking some larger issue.

On Saturday, [XXX], at approximately [XXX], I drove my 2022 Hyundai Ioniq 5 north on [XXX] . The car was operating normally. I stopped at the red light at the corner of [XXX] and noticed a large red circle with a "Check electrical system" warning on the driver's display screen. When the traffic light turned green, I pressed the accelerator pedal, and the car did not move. I looked at the "Park, Neutral, Reverse, Drive" shifter. The "P" was lit up, indicating the car was in "Park." I attempted to switch to "Drive," and the status indicator remained in "P." I then pushed the "EV START STOP" switch to see if I could cycle the vehicle off and then back on to clear the problem. The switch had no effect. [XXX] is a busy four-lane, undivided street near the University of Colorado at Boulder campus. I selected the hazard flashers and called 911 to alert the Boulder Police Department that I was in a car that was immobilized in the middle of the right-hand northbound lane. Cars had to swerve to avoid me. The Police Department dispatched a vehicle that arrived 10 minutes later, pulled up behind me, and put its flashing lights on to alert traffic. While waiting for the tow truck, I received another alert on the driver's display that informed me that the 12-volt battery was nearly completely discharged, and I had 10 minutes of power left. The warning counted the remaining minutes to 0, and the displays shut down. From the first warning message to the shutdown, I could not turn the car system off or shift the car out of the park. The tow company had to put dollies under the rear wheels of the Ioniq 5 and lift the front end off the ground to tow the vehicle, as all four wheels were locked. The car was towed to Crossroads Hyundai in Loveland, Colorado. It had just been serviced to address all the recall issues, including the ICCU software update. The car has approximately 16,000 miles on it. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)