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2016 Hyundai Tucson

Owner reports · Recalls · Investigations

More warning signs than most Tucson years

Owner complaints for the 2016 Hyundai Tucson are substantially higher than the model-year median of 180.5.

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When problems were reported

Mileage at the reported incident

832 reports with mileage · 785 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Power Train. Review the 516 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 423 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 227 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

14 crash reports24 fire reports6 injury reports

Power Train complaints

516 reports
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100 miles · Jul 5, 2016
EnginePower Train

WHEN IN DRIVING, COMING TO A STOP, THE CAR LUNGES FORWARD, MUST KEEP FOOT ON BRAKE, HYUNDAI SAYS THIS IS NORMAL FOR THE TUCSON. I THINK THIS IS A PROBLEM. REPORTED IT IN MY FIRST SERVICE AND TOLD IT'S HYUNDAI'S PROBLEM. IF I HIT SOMETHING IT'S MY PROBLEM.

NHTSA ODI #10882711

2,500 miles · Jul 5, 2016
Power Train

INTERMITTENT ISSUE WITH TRANSMISSION FAILING TO ENGAGE 1ST GEAR FROM A STOP. ENGINE REVS BUT NO POWER GOES TO THE WHEELS. HAPPENED THREE TIMES IN THE LAST TWO WEEKS ON A VEHICLE WITH 2500 MILES. RESTARTING THE VEHICLE RESOLVED THE ISSUE ONCE BUT NOT ON THE OTHER OCCASIONS.

NHTSA ODI #10882520

16,669 miles · Jul 4, 2016
Power Train

FAILS TO FULLY ENGAGE GEARS, FEEL LIKE TRANSMISSION HAS SLIPPED OUT OF GEAR, WON'T ALWAYS GO INTO FIRST GEAR WHEN STARTING OUT. OR GOES INTO FIRST AND SECOND IS NOT THERE, NO POWER TO MOVE UNTIL FOOT IS LIFTED OFF ACCELERATOR, WAIT A FEW SECONDS THEN TRY AGAIN.

NHTSA ODI #10882480

3,700 miles · Jul 4, 2016
Power Train

THE PROBLEM IS THE DUAL CLUTCH TRANSMISSION (DCT). AT TIMES, WHEN PROGRESSING FROM A STOP (STATIONARY), THE ENGINE RPM INCREASES NORMALLY BUT THE TRANSMISSION DOES NOT IMPART MOTION TO THE WHEELS. DEALER CANNOT DUPLICATE THE PROBLEM. THERE ARE NUMEROUS COMPLAINTS ON NHTSA WEBSITE AND ON THE HYUNDAI FORUM WEBSITE. HYUNDAI IS SILE…

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THE PROBLEM IS THE DUAL CLUTCH TRANSMISSION (DCT). AT TIMES, WHEN PROGRESSING FROM A STOP (STATIONARY), THE ENGINE RPM INCREASES NORMALLY BUT THE TRANSMISSION DOES NOT IMPART MOTION TO THE WHEELS. DEALER CANNOT DUPLICATE THE PROBLEM. THERE ARE NUMEROUS COMPLAINTS ON NHTSA WEBSITE AND ON THE HYUNDAI FORUM WEBSITE. HYUNDAI IS SILENT ABOUT THIS PROBLEM. THIS IS A SERIOUS SAFETY DEFECT. HYUNDAI NEEDS TO RECALL THIS DCT FOR REPAIR/REPLACEMENT IMMEDIATELY.

NHTSA ODI #10882451

3,100 miles · Jul 1, 2016
Power Train

ON FRIDAY, JUNE 17, MY TUCSON WAS PARKED OUTSIDE FROM 4 P.M. TO 7 P.M. AND THE OUTSIDE TEMPERATURE WAS IN THE LOWER 90'S. WE THEN GOT IN THE CAR AND DROVE APPROXIMATELY 2 MILES AT 25 MILES PER HOUR TO THE REAR GATE OF THE COMMUNITY. WE STOPPED AT THE REAR GATE TO WAIT FOR IT TO OPEN, HOWEVER IT DID NOT OPEN AS IT DID NOT SENSE …

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ON FRIDAY, JUNE 17, MY TUCSON WAS PARKED OUTSIDE FROM 4 P.M. TO 7 P.M. AND THE OUTSIDE TEMPERATURE WAS IN THE LOWER 90'S. WE THEN GOT IN THE CAR AND DROVE APPROXIMATELY 2 MILES AT 25 MILES PER HOUR TO THE REAR GATE OF THE COMMUNITY. WE STOPPED AT THE REAR GATE TO WAIT FOR IT TO OPEN, HOWEVER IT DID NOT OPEN AS IT DID NOT SENSE THE PRESENCE OF THE CAR. SO I ATTEMPTED TO BACK UP BY PLACING THE CAR IN REVERSE AND DEPRESSING THE ACCELERATOR. THE CAR RPM WENT TO 4000 AND THE CAR DID NOT MOVE. SO I TOOK FOOT OFF THE ACCELERATOR, AND UPON DEPRESSING THE ACCELERATOR AGAIN, THE CAR RPM WENT TO AGAIN TO 4000 HOWEVER AGAIN THE CAR DID NOT MOVE. MY WIFE WAS WITH ME ASKING 'WHAT IS WRONG WITH THIS CAR IT IS NOT MOVING AND CARS ARE BEHIND US'. I THEN PLACED THE CAR IN PARK FOR ABOUT 30 SECONDS. THE GATE WAS NOW OPENED, SO I PLACED THE CAR IN DRIVE AND DEPRESSED THE ACCELERATOR. THE CAR RPM WENT TO 3000 TO 4000 AGAIN, HOWEVER THE CAR BEGAN TO MOVE EXTREMELY SLOWLY, UNDER 5 MPH. IT THEN SHIFTED, JERKING AS IT MOVED FORWARD AND SHIFTING. AFTER TRAVELING ABOUT 200 FEET THE CAR BEGAN TO SHIFT AND DRIVE IN A NORMAL MANNER. THIS IS THE 6TH OR 7TH TIME THIS HAS OCCURRED, HOWEVER USUALLY HAPPENS WHEN ATTEMPTING TO GO FORWARD FROM A STOP. THE CAR ACTS LIKE IT IS IN NEUTRAL AND DOES NOT MOVE, ENGINE REVS UP BUT DOES NOT MOVE. TAKEN THE CAR TO THE DEALERSHIP 3 TIMES, HOWEVER THE PROBLEM IS INTERMITTENT AND DOES NOT HAPPEN AT THE DEALERSHIP.. THE CHECK OUT THE CAR AND STATE THAT THEY FIND NO ERROR CODES AND THE CAR IS OPERATING NORMALLY.

NHTSA ODI #10882162

400 miles · Jul 1, 2016
Power Train

WE RECENTLY PURCHASED THIS VEHICLE. AFTER DRIVING THIS VEHICLE TWO WEEKS, WE EXPERIENCED SEVERAL INSTANCES IN WHICH THE DCT TRANSMISSION FAILED. WHILE ATTEMPTING TO CROSS FOUR LANES OF TRAFFIC, VEHICLE STALLED WHILE ATTEMPTING TO ENTER TRAFFIC FLOW. IN ANOTHER CASE, THE VEHICLE FAILED TO RESPOND WHEN IT WAS PUT INTO REVERSE. SE…

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WE RECENTLY PURCHASED THIS VEHICLE. AFTER DRIVING THIS VEHICLE TWO WEEKS, WE EXPERIENCED SEVERAL INSTANCES IN WHICH THE DCT TRANSMISSION FAILED. WHILE ATTEMPTING TO CROSS FOUR LANES OF TRAFFIC, VEHICLE STALLED WHILE ATTEMPTING TO ENTER TRAFFIC FLOW. IN ANOTHER CASE, THE VEHICLE FAILED TO RESPOND WHEN IT WAS PUT INTO REVERSE. SEVERAL OTHER OCCASIONS THE TRANSMISSION SLIPPED AND FAILED TO CHANGE GEARS. THIS CAR IS VERY UNSAFE AND WE HAVE NO CONFIDENCE IN HYUNDAI. THIS VEHICLE WAS RETURNED TO THE DEALERSHIP AND AT THAT TIME THEY FOUND NO PROBLEM. THE CAR IS CURRENTLY IS IN THEIR CARE, AWAITING FURTHER CONSULTATION FROM HYUNDAI CORPORATE. HOWEVER, WE WERE TOLD THERE IS NO CURRENT FIX FOR THE PROBLEM. WE ARE CURRENTLY DISMAYED AND MAY BE SEEKING LEGAL ADVICE..

NHTSA ODI #10882039

4,800 miles · Jul 1, 2016
Power Train

JUST LIKE SO MANY OTHER COMPLAINANTS HERE: MY 2016 HYUNDAI TUCSON FAILED TO MOVE FORWARD AFTER BEING STOPPED AT A RED LIGHT AND ULTIMATELY HAD TO BE TOWED TO THE DEALERSHIP. THE DEALER "FIXED" THE ISSUE BY RESETTING THE TRANSMISSION MODULE. HOWEVER, THEY COULD NOT INDICATE WHY IT FAILED IN THE FIRST PLACE NOR COULD THEY GUAR…

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JUST LIKE SO MANY OTHER COMPLAINANTS HERE: MY 2016 HYUNDAI TUCSON FAILED TO MOVE FORWARD AFTER BEING STOPPED AT A RED LIGHT AND ULTIMATELY HAD TO BE TOWED TO THE DEALERSHIP. THE DEALER "FIXED" THE ISSUE BY RESETTING THE TRANSMISSION MODULE. HOWEVER, THEY COULD NOT INDICATE WHY IT FAILED IN THE FIRST PLACE NOR COULD THEY GUARANTEE THAT IT WOULD NOT HAPPEN AGAIN. JUDGING BY THE NUMBER OF COMPLAINTS HERE AND AT HYUNDAI-FORUMS, THIS IS BECOMING A WIDESPREAD ISSUE THAT NEEDS TO BE ADDRESSED BY HYUNDAI. IT IS A POTENTIALLY DANGEROUS PROBLEM IF THE VEHICLE BECOMES IMMOBILE WHILE TURNING LEFT IN FRONT OF ONCOMING TRAFFIC. HYUNDAI FORUMS THREAD: HTTP://WWW.HYUNDAI-FORUMS.COM/2016-TUCSON-IX35-MODELS/454074-DANGEROUS-HORRIBLE-DCT.HTML SAMPLE VIDEOS: HTTPS://YOUTU.BE/TCVTR_ZCYRS HTTPS://YOUTU.BE/LZX0M58VULG HTTPS://YOUTU.BE/H11K6UH1QZW

NHTSA ODI #10881964

2 miles · Jun 30, 2016
Power Train

HAVING AN ISSUE WITH THE TRANSMISSION. WHEN YOU GO TO ACCELERATE IT STAYS IN NEUTRAL. THIS HAPPENS WHEN MOVING. SOMETIMES IT DOWNSTHITS FOR NO REASON WHICH MADE YOU SLOW DOWN. TROUBLE SHIFTING GEARS. ALSO WHEN YOU TRY TO MOVE THE DRIVING STICK TO MANUAL IT WON'T SWITCH OVER.

NHTSA ODI #10881857

2,400 miles · Jun 30, 2016
Power Train

IN TWO SEPARATE INCIDENTS ABOUT A MONTH APART, I WAS STOPPED AT A TRAFFIC LIGHT BEHIND SEVERAL OTHER CARS. WHEN THE LIGHT CHANGED AND I PRESSED THE ACCELERATOR, THE ENGINE REVVED, BUT THE AUTOMATIC TRANSMISSION DID NOT ENGAGE AND THE CAR WOULD NOT GO FORWARD. IT WOULD GO BACKWARD, BUT NOT FORWARD. A WARNING LIGHT CAME ON FOR A…

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IN TWO SEPARATE INCIDENTS ABOUT A MONTH APART, I WAS STOPPED AT A TRAFFIC LIGHT BEHIND SEVERAL OTHER CARS. WHEN THE LIGHT CHANGED AND I PRESSED THE ACCELERATOR, THE ENGINE REVVED, BUT THE AUTOMATIC TRANSMISSION DID NOT ENGAGE AND THE CAR WOULD NOT GO FORWARD. IT WOULD GO BACKWARD, BUT NOT FORWARD. A WARNING LIGHT CAME ON FOR A FEW MINUTES THAT SAID THE TRANSMISSION FLUID WAS TOO HOT AND I SHOULD STOP THE CAR SAFELY. (LIKE IT WASN'T ALREADY UTTERLY STOPPED, IN THE MIDDLE OF A LEFT-TURN LANE.) AFTER A FEW MINUTES, THE WARNING LIGHT WENT OFF, BUT THE CAR STILL WOULD NOT GO FORWARD, FIRST INCIDENT OCCURRED AFTER ABOUT 2,400 MILES. THE DEALER SAID THAT HYUNDAI TECHNICAL TOLD HIM THERE WAS AN UPDATE TO THE SENSOR SOFTWARE THAT WOULD FIX THE PROBLEM. HE SAID HE PERFORMED THE UPDATE. SECOND INCIDENT WAS ABOUT A MONTH AND 600 MILES LATER. DIFFERENT TRAFFIC LIGHT, DIFFERENT LEFT TURN LANE, SAME PROBLEM. THIS TIME, AS I WAITED 2 HOURS FOR A TOW TRUCK, AFTER ABOUT 25 MINUTES, THE CAR SPONTANEOUSLY DROPPED BACK INTO GEAR AND I WAS ABLE TO DRIVE IT 2-3 BLOCKS BEFORE IT STOPPED DEAD AGAIN AT ANOTHER TRAFFIC LIGHT. IN THE REMAINING 90 MINUTES WHILE I WAITED FOR THE TOW TRUCK, THE CAR WOULD SPORADICALLY BE ABLE TO LURCH FORWARD A FEW FEET IN LOW GEAR BEFORE DROPPING OUT OF GEAR AGAIN AND STOPPING. THE TOW TRUCK DRIVER WHO TRIED TO DRIVE THE CAR UP THE TRUCK RAMP EXPERIENCED THE SAME PROBLEM AND VERIFIED IT. CAR HAS BEEN AT THE DEALER NOW FOR OVER A WEEK. TODAY, HYUNDAI TECHNICAL GAVE IT A "FAST TRACK" NUMBER. SERVICE MANAGER IS STILL WAITING FOR DIRECTION FROM HYUNDAI TECHNICAL FOR WHAT TO DO TO FIX IT. HE TOLD ME THAT MY CAR IS NOT THE FIRST CAR HE HAS SEEN WITH THIS PROBLEM. AND WHILE MY CAR HAS BEEN IN HIS SHOP THIS WEEK, ANOTHER VEHICLE HAS COME IN WITH THE SAME PROBLEM.

NHTSA ODI #10881816

400 miles · Jun 29, 2016
Power Train

THIS IS AN INTERMITTENT ISSUE WITH THE DCT TRANSMISSION. AFTER STOPPING AT A STOPLIGHT, THE VEHICLE WILL NOT MOVE AFTER RELEASING BRAKE/APPLYING GAS PEDAL. VEHICLE SHOWS THAT IS IN "D". TRIED PUTTING THE VEHICLE IN "P" AND BACK IN "D"; VEHICLE STILL DOES NOT MOVE. PUTTING THE SHIFTER IN MANUAL MODE STILL SHOWS "D" INSTEAD OF …

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THIS IS AN INTERMITTENT ISSUE WITH THE DCT TRANSMISSION. AFTER STOPPING AT A STOPLIGHT, THE VEHICLE WILL NOT MOVE AFTER RELEASING BRAKE/APPLYING GAS PEDAL. VEHICLE SHOWS THAT IS IN "D". TRIED PUTTING THE VEHICLE IN "P" AND BACK IN "D"; VEHICLE STILL DOES NOT MOVE. PUTTING THE SHIFTER IN MANUAL MODE STILL SHOWS "D" INSTEAD OF THE ACTUAL GEAR IT IS IN. TOOK THE VEHICLE TO A HYUNDAI DEALER. SERVICE DEPARTMENT COULD NOT REPLICATE THE ISSUE SO THEY DID NOTHING TO RESOLVE ISSUE.

NHTSA ODI #10881598

Official recalls

5

20V543000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Sep 4, 2020

Hyundai Motor America (Hyundai) recalled certain 2019-2021 Tucson vehicles on September 4, 2020. On December 30, 2020, Hyundai expanded the recall population, and added certain 2016-2018 Tucson vehicles. The Anti-lock Brake Hydraulic Electronic Control Unit (HECU) could corrode internally and cause an electrical short, possibly resulting in an engine compartment fire.

Consequence & remedy

Consequence: An engine compartment fire can increase the risk of injury or crash.

Remedy: Hyundai will notify owners, and dealers will replace the HECU fuse. For 2019-2021 model years, the Electronic Stability Control (ESC) software will also be updated. Recall repairs will be performed free of charge. Owners are advised to park outside and away from structures as a precaution until the recall repair is complete. The recall began November 2, 2020. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 195.

16V842000 · Electrical System:wiring; Trailer Hitches

Nov 21, 2016

Hyundai Motor America (Hyundai) is recalling certain model year 2016-2017 Tucson vehicles manufactured May 19, 2015, to November 14, 2016, and 2017 Santa Fe vehicles manufactured November 28, 2015, to November 14, 2016. The affected vehicles may be equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result, in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence & remedy

Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the affected accessory trailer hitch wiring harnesses, free of charge. The recall is expected to begin January 13, 2017. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 153.

Additional source detail variants (2)

Trailer Hitches

Hyundai Motor America (Hyundai) is recalling certain model year 2016-2017 Tucson vehicles manufactured May 19, 2015, to November 14, 2016, and 2017 Santa Fe vehicles manufactured November 28, 2015, to November 14, 2016. The affected vehicles may be equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result, in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the affected accessory trailer hitch wiring harnesses, free of charge. The recall is expected to begin January 13, 2017. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 153.

Electrical System:wiring

Hyundai Motor America (Hyundai) is recalling certain model year 2016-2017 Tucson vehicles manufactured May 19, 2015, to November 14, 2016, and 2017 Santa Fe vehicles manufactured November 28, 2015, to November 14, 2016. The affected vehicles may be equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result, in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the affected accessory trailer hitch wiring harnesses, free of charge. The recall is expected to begin January 13, 2017. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 153.

16V628000 · Electrical System:software; Power Train:automatic Transmission:control Module (tcm/pcm/tecm)

Aug 30, 2016

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 20, 2015 through May 31, 2016 and equipped with a 7-speed EcoShift Dual Clutch Transmission. Certain driving conditions and high temperatures may cause the vehicle to not move if the accelerator pedal is pressed and released repeatedly.

Consequence & remedy

Consequence: Inability to move the vehicle while in traffic may increase the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the Transmission Control Module software, free of charge. The recall is expected to begin on October 28, 2016. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 149.

Additional source detail variants (2)

Electrical System:software

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 20, 2015 through May 31, 2016 and equipped with a 7-speed EcoShift Dual Clutch Transmission. Certain driving conditions and high temperatures may cause the vehicle to not move if the accelerator pedal is pressed and released repeatedly.

Consequence: Inability to move the vehicle while in traffic may increase the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the Transmission Control Module software, free of charge. The recall is expected to begin on October 28, 2016. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 149.

Power Train:automatic Transmission:control Module (tcm/pcm/tecm)

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 20, 2015 through May 31, 2016 and equipped with a 7-speed EcoShift Dual Clutch Transmission. Certain driving conditions and high temperatures may cause the vehicle to not move if the accelerator pedal is pressed and released repeatedly.

Consequence: Inability to move the vehicle while in traffic may increase the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the Transmission Control Module software, free of charge. The recall is expected to begin on October 28, 2016. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 149.

16V348000 · Latches/locks/linkages:hood:latch

May 24, 2016

Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Tucson vehicles manufactured May 19, 2015 to March 14, 2016. In the affected vehicles, if the primary hood latch has been released, and the vehicle is driven, the secondary hood latch may not hold adequately secure the hood to prevent it from opening while the vehicle is in motion.

Consequence & remedy

Consequence: If the primary hood latch is inadvertently released and the secondary latch cannot secure the hood, the hood may unexpectedly open while driving, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will replace the secondary hood latch, free of charge. The recall began on June 30, 2016. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 145.

16V147000 · Exterior Lighting:tail Lights

Mar 10, 2016

Hyundai Motor America (Hyundai) is recalling certain model year 2016 Hyundai Tucson vehicles manufactured May 26, 2015 to January 15, 2016 and equipped with an accessory trailer hitch harness either included with the accessory trailer hitch or sold as a service part. In the affected vehicles, when the vehicle's engine is running and the brake lights are illuminated, if the turn signal is activated, the trailer turn signal lights will either turn off or remain continuously illuminated (not flash). As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard Number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence & remedy

Consequence: Failure to illuminate the trailer's turn signal lights would prevent the communication of the driver's intent, increasing the risk of a crash.

Remedy: Hyundai will notify owners, and dealers will update the tow hitch harness, free of charge. The recall began on May 2, 2016. Owners may contact Hyundai customer service at 1-855-371-9640. Hyundai's number for this recall is 142.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

DP22003 · Loss Of Motive Power

Opened Sep 12, 2022 · Closed Dec 12, 2023

Status: closed (inferred from source dates) · Engine

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.

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