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Hyundai issues major Santa Fe recall after crash test reveals fire hazard
Hyundai Motor America has announced a recall affecting 135,386 U.S.-market Santa Fe crossovers equipped with the 2.5-liter turbocharged inline-four. The recall covers 2024 and 2025 model-year vehicles built between December 28, 2023 and July 7, 2025 after a safety review found a potential electrical fire risk in certain crash scenarios.
The problem traces to the starter motor assembly: the protective cover over the starter's B+ terminal may not be fully seated. If the cover shifts during a front impact that deforms the engine compartment, the exposed terminal can contact the cooling fan assembly and cause a short circuit — a condition that, in theory, could lead to thermal events.
How the defect was discovered
The issue came to light following a front barrier crash test conducted by the National Highway Traffic Safety Administration (NHTSA). During the post-crash inspection, investigators detected smoke in the engine bay, prompting the agency to contact Hyundai’s technical center on November 20, 2024. Hyundai later traced the concern to a wiring-harness assembly supplied by Hyundai Motor Manufacturing Alabama (part number 91850R6020).
Importantly, Hyundai says there have been no confirmed field incidents tied to this condition to date.
What owners can expect
- Dealers will be instructed to inspect the starter motor B+ terminal cover and, if necessary, reinstall it properly.
- The inspection and any corrective work will be performed free of charge for affected owners and lessees.
- Dealer guidance and customer notification letters are scheduled to be issued on December 1, 2025. VINs for the affected vehicles were uploaded to Hyundai’s U.S. customer portal on October 4, 2025.
Hyundai reports the production issue was addressed in June 2025 by updating installation and inspection processes to prevent recurrence.
About the Santa Fe (MX5) and market positioning
Described by Hyundai as an “adventurous compact SUV,” the fifth-generation Santa Fe (internally MX5) received a redesign for the 2024 model year. Built in multiple factories — including Montgomery, Alabama; Ulsan, South Korea; and Beijing, China — the Santa Fe shares the Hyundai N3 platform with the smaller Tucson and the Santa Cruz.
Powertrain options include naturally aspirated GDi and turbocharged T-GDi engines, along with hybrid and plug-in hybrid variants that use lithium-ion polymer battery cells. For buyers sticking with combustion power in the U.S., the 2.5-liter turbo produces 277 horsepower and 311 lb-ft (422 Nm) of torque at 4,000 rpm.
Pricing and trim highlights
In the U.S. the 2026 Santa Fe starts at $34,800 for the SE front-wheel-drive model. Opting for Hyundai’s HTRAC all-wheel-drive system adds $1,800; a destination charge of $1,600 applies across the range. The top combustion-only Calligraphy trim brings Nappa leather, 21-inch wheels, Remote Smart Parking Assist, BlueLink+, and other premium features.
Why this matters
Recalls like this underline how a seemingly small assembly misalignment can have outsized safety implications. Even though no crashes linked to this issue have been reported in the field, Hyundai and federal regulators moved to correct the risk proactively — a reminder that post-crash testing and supplier quality control remain vital to vehicle safety.
If you own a Santa Fe within the production window above, check Hyundai’s VIN lookup or contact your dealer. The inspection is quick, free, and intended to eliminate any chance of electrical shorting caused by an improperly seated starter cover.
"Safety is our priority," Hyundai says, and this recall demonstrates the automaker's effort to address a localized hardware issue before it can affect customers.
Source: autoevolution
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