2022 Hyundai Santa Fe Hybrid problems

“The vehicle has suffered a catastrophic structural manufacturing defect involving a transmission case half seal failure. The transmission is actively seeping/leaking fluid directly from the factory-mated case assembly line seal. This presents a severe, progressive safety hazard. Transmission fluid leaking from the case half migrates along the underbody of the vehicle and directly coats hot exhaust and powertrain components during highway operation. This creates an immediate risk of under-hood smoke, thermal degradation, component stalling, or a potential vehicle fire at high speeds. Certified diagnostic inspection confirms this is a factory assembly defect (defective RTV sealant application or improper factory bolt torque) and not mechanical wear-and-tear or driver neglect. The vehicle currently has 88,000 miles, but the structural failure was first physically documented by a licensed facility at 59,870 miles. The manufacturer (Hyundai Motor America) has currently refused to honor the powertrain failure, forcing the vehicle to remain on the road with an active powertrain fluid leak risk.”

“While accelerating at a light, the accelerator became unresponsive, only propelling the vehicle a couple miles per hour. I was not able to pull over, as I was in the left lane of a very busy road. After about 15 seconds of lack of acceleration, the accelerator responded enough for me to pull over. I’m glad this incident did not occur on a highway, during a turn, or other hazardous situations. Dash displayed, “Check hybrid system. Pull over safely”. There was no indication or issue with the vehicle prior to this. I haven’t had any issues since I bought it several months ago. I’ve read reports of this same issue happening with this same model. I have a scheduled date for inspection.”

“vehicle will not change out of EV electric mode and return to gas power causing hybrid battery drains to zero, vehicle loses acceleration, you can push the gas pedal to the floor and you have no acceleration, very UNSAFE when you are in traffic, no power to maneuver or avoid other vehicles quickly if needed, potential for accidents, hybrid system warning lights and alarms go on, have to try and pull over safely, battery will not recharge or takes a very long time to do so, only recourse is to shut vehicle off and restart which seems to reset vehicle, which in turn does not leave any warning lights other than codes on to show dealer, very dangerous to lose all acceleration capacity while in traffic, this has happened multiple times with the latest being today 3/23/25, vehicle is available for you to inspect, have had other powertrain codes issues as well, dealer has replaced fuel pump and erg valve but it does not resolve this hybrid issue, this battery drain issue has occurred multiple times but no resolution, help!”

“Occasionally the cruise control will go off. Sometimes it will reset itself & other times, the driver has to initiate. I reported to the Hyundai Manuf. last yr. & also had 2 separate dealers take a look & problem has not been resolved.”

“Headed to my work ,outside temp 26 deg F, when on hiway entrance ramp, vehicle lost all acceleration. Vehicle is a hybrid, condition no warning lights on dash, vehicle was stuck in EV mode, which the ICE engine would not start to help as normally would do. Hybrid battery began draining very quickly. There was a semi truck right behind me accelerating hard to get on highway .This time I managed to pull over on the debris filled shoulder before the system fully shut down as it has done before with the warning ️ HYBRID SYSTEM FAILURE, PULL OVER NOW ! and loud alarm going off. This is a serious loss of total motive power, which I've reported to Hyundai Corporate, and dealerships for repair before, to which they say " we can't duplicate, all systems are fine", and blame me for the problem. Hyundai has washed their hands of this dangerous situation and won't help me. This is the 5th occasion of this problem, I now know from my experience and reading Hyundai forums this issue is wide spread among Hyundai Tucson and Santa Fe hybrids, with some places replacing parts, that doesn't fix the issue. I know how to react by pulling over immediately, shut off the vehicle…”

“The driver-side seat belt buckle on my 2022 Hyundai Santa Fe will not latch. This is a safety-critical failure under FMVSS 209/210. The vehicle has not been in a collision. The dealership and Hyundai Consumer Affairs bot stated that the seat belts are only covered under te 5 yr/60K warranty and refused to treat this as a safety defect. The buckle failure prevents proper restraint and poses a serious safety risk.”