2023 Hyundai Ioniq 5

I purchased my Hyundai Ioniq 5 on [XXX]. Since then, I have experienced repeated and dangerous failures of the air-conditioning system, which Hyundai and the selling dealership have failed to properly diagnose or repair. On [XXX], while driving, I heard a very loud banging noise coming from the front passenger side of the vehicle. Immediately afterward, the air-conditioning system completely shut down and stopped producing cold air. Before the extreme Arizona heat began, I repeatedly asked Hyundai on Bell Road in Glendale to properly diagnose the A/C system due to ongoing concerns. Despite the vehicle being under warranty, the technician told me I would have to pay a diagnostic fee before they would evaluate the A/C. As a result, the underlying problem was not properly diagnosed or repaired. On [XXX], the exact same failure occurred again the same loud banging noise followed by a complete loss of air conditioning. The vehicle was taken to Hyundai on Bell Road in Glendale a total of four (4) times, spending 33 days out of service for the same issue. Despite this, the dealership failed to repair the vehicle. On several visits, the car was simply parked, and the dealer later claimed it had been “fixed” one time, even though the problem continued. This defect created a serious safety hazard. During one incident, while driving the vehicle in extreme heat to the dealership for repair, the interior temperature became dangerously high. My phone overheated and shut down, and I nearly passed out while driving. Hyundai Corporate has been unresponsive and dismissive. Rather than addressing the repeated failures and safety risks, I was referred to Lemon Law, where my claim was denied, despite the extensive repair history and time out of service. Instead of repairing the defect or taking responsibility, both the dealership and Hyundai Corporate pressured me to trade in the vehicle and move on, without resolving the underlying problem. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

INCIDENT DESCRIPTION: On November 24, 2025, while driving at ~60 mph on NYS Route 17 (highway) with ~15% battery charge, my 2023 Hyundai IONIQ 5 suddenly entered limp mode and lost motive power. The high-voltage battery state of charge dropped instantly from ~10-15% to 0%, triggering error code P1B9600 (HV battery cell imbalance—cells failing to charge/discharge properly). I was unable to fully remove the vehicle from the roadway. My elderly mother was a passenger; a passing tractor-trailer came within 1 ft of striking us when disabled. NY State Police responded (report available). Required $300 tow to the Hyundai dealer, stranding us 150 miles from home.//PRIOR RELATED FAILURES: 1. November 14, 2025: Stranded due to ICCU failure (recall 24V-868 related) (stranded on NYS State Route 444). 2. September 15, 2025: Same P1B9600 code/limp mode/power loss; stranded in the middle of active travel lane of NYS 444; NY State Police report filed. 3. August 2025: Initial HV battery-related sudden power loss; stranded on Interstate 90 Eastbound (Erie, PA area). Despite repairs (September 2025 ICCU/"limp mode" software updates; October 2025 ICCU/high-voltage fuse replacement under recall 24V-868), defects persist. The vehicle charge rate also appears low and the battery consumption rate seems high.// CURRENT STATUS: Dealer (Vision Hyundai) confirmed high-voltage battery pack defective, requiring full replacement. Vehicle purchased new October 2024, under warranty. In service since mid-November 2025 (>30 days downtime). Provided loaner now, but prior rentals unreimbursed.//SAFETY RISK: Repeated sudden power losses create extreme highway crash risk, especially with vulnerable passengers. I am a licensed professional mechanical engineer, and can provide technical logs, repair orders, police reports upon request.The issues I have experienced appear to be linked to ongoing ICCU/HV system issues in IONIQ 5. I respectfully request expansion of the recall investigation.

My vehicle has experienced three separate failures of the Integrated Charging Control Unit (ICCU) and two separate 12-volt battery failures. All manufacturer recalls related to the ICCU have been completed. Each of these five events required towing and resulted in either an inability to start the vehicle, or a sudden loss of power while driving, including limp mode. During multiple events, the vehicle displayed a warning message stating “Stop vehicle and check power supply” accompanied by a red battery icon. The sudden loss of power created a serious safety risk to me and to others on the road, particularly when the vehicle lost propulsion unexpectedly. In each case, the vehicle became unsafe or impossible to operate. For every incident, the problem was diagnosed by authorized Hyundai dealer, and I was informed that the issue had been repaired. Despite these repairs and recall actions, the same failures continued to occur. These repeated ICCU and 12-volt battery failures demonstrate an ongoing electrical system defect that has not been permanently corrected and presents a continuing risk of sudden power loss.

On 12/13 while driving back home at a red light at night, we heard a loud pop at the driver's rear side and suddenly the dash displayed a warning stating "Check electric vehicle system". The car then would not drive past 25 mph and kept flashing the warning. We got it home safe, and planned on dropping it off at the dealership the next day after jumping it. The next day however, after multiple attempts to jump the car's battery, it would not start enough to move it. The car would start and then flash a warning saying that the 12V battery voltage is low and then shut off again. It had to be towed on 12/15 to the dealership where they will be doing an diagnosis.

While driving on the freeway I heard a pop and a saw a warning notification on the dashboard to check the vehicles electrical system. This was followed by a warning that power was limited which resulted it the vehicle speed decreasing to 30mph, and finally a notice to stop the vehicle immediately. All of this occurred in about 5 minutes time. Thankfully, I was able to pull over to the side of the road without an accident. After this the vehicle became inoperable including hazard flashers. I had to wait on the side of the freeway for about an hour to get a tow. The vehicle was towed to a dealer which confirmed that the ICCU and high voltage fuse were faulty. My safety during this process was put at risk because A) during a snow storm I had to pull the vehicle over to the side quickly across 4 lanes of traffic and B) then remain parked on the shoulder with limited ability to notify other drivers that I was on the shoulder. The dealer has confirmed the failure, the vehicle is available for inspection, and the manufacturer has not inspected the component.

A water bottle spilled from back seat during sudden deceleration due to traffic. Thd bottle hit the back of the drivers seat and some of the contents spilled, I felt moisture from under seat on my ankles. Shortly after the car systems started reporting they were not working. By the time I returned home not even the turn signals worked and I could log turn off the EV. Car towed to desler who determined there are critical electrical connectors under the seat that showed signs of a short and corrosion. This is not covered by manufactures warranty and thd dealer presented me with an estimate over $11,000 to replace the drivers seat and floor wiring harnesses. I also filed a chain under my comprehensive insurance which was denied as the insurance company believes the corrosion was ongoing vs an all of the sudden issue. I believe the Ioniq has design flaws as critical connections should be better protected. Kids in thd back seat and front seats can frequently spill things and this fat seems way to fragile with this type of design. This problem occurred October 9th and the car is still with the dealer I need help please.