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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. Â§ 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 â 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:  â¢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; â¢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; â¢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; â¢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; â¢The proximity of the defect to hybrid drivetrain components warrants evaluation for potential regulatory compliance

HYUNDAI SANTA FE HYBRID 2023 SUSPENSION

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

HYUNDAI SANTA FE HYBRID 2023 FUEL/PROPULSION SYSTEM

The vehicle will not accelerate and comes to a complete stop while driving. Within days, it displayed âCheck Hybrid System. Stop safelyâ and lost propulsion while driving.

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.

On September 4, 2025 as I pulled on to Interstate I-70 my car suddenly lost power. Gas engine died. Loud attention sound started. Instrument cluster started flashing red with message  "EV system failure, stop immediately" EV battery showed full depletion although a moment before it showed about 75% power. There was only enough propulsion to keep moving slowly. Since this was a construction zone the shoulder was blocked off and roadway was reduced to only one lane. I had no where to go. A large truck narrowly avoided rear ending me. I was scared and felt helpless. Eventually I was able to pull off and shut off the car. It was able to be re-started immediately with no warning indicators and EV battery power restored.  This loss of power has happened 6 times before during the time I have owned the car. Last time was in March 2025.  Each previous time it happened I was traveling at about 35 miles per hour and while annoying I did not fear for my life. On March 6, 2025 I had the dealer, McCarthy Hyundai, check out this problem. There were no detectable problems or problem codes. I was told that it might have been caused by the oil dip stick not being fully seated. It was obvious they had no clue what caused this but that I should come back if it happened again. I have reported this to Hyundai customer service who would not confirm that this was a problem encountered by many others. From looking at reports on the internet, my problem is not unique except for being life thretening. Customer service had me bring it back to dealer. Yesterday, September 24, I picked up the vehicle whohad it for a week to try to fix the problem. Once again there were no error codes. Only problem they found was an ignition coil which needed to be replaced. They could not give a convincing explaination of how a bad ignition coil could cause a complete failure of the gas motor and EV system or why if the coil was sole problem that it would only cause this failure every 3 to 6 months. Please help!

HYUNDAI SANTA FE HYBRID 2023 ENGINE

2023 Hyundai Santa Fe Hybrid — vehicle data sourced from FuelEconomy.gov.

The 2023 Hyundai Santa Fe Hybrid offers a compelling blend of efficiency and practicality, boasting an impressive 32 MPG combined. Its capable All-Wheel Drive system and versatile SUV body style make it a solid choice for families seeking a safe and reliable vehicle.

	2021	2022	2023
Price	—	—	$36,700
Engine Capacity	1.6L	1.6L	1.6 L
Fuel Type	Regular	Regular Gasoline	Regular Gasoline
Transmission	Automatic (AM-S6)	Automatic (AM-S6)	6 speed automatic
Body Type	Small Sport Utility Vehicle 4WD	Small Sport Utility Vehicle 4WD	SUV

Hyundai Santa Fe Hybrid (2023) Specifications