Hyundai Fire Risk Results in Santa Fe Recall Impacting More Than 135,000 Vehicles

Signs of at least one thermal event were discovered in a Hyundai Santa Fe SUV during a post-test vehicle inspection.

A recall affecting more than 135,000 Hyundai Santa Fe vehicles has been issued by the manufacturer due to an installation defect, which could cause a short-circuit and increase the risk of a fire.

The U.S. National Highway Traffic Safety Administration (NHTSA) announced the Hyundai Santa Fe recall on October 2, warning that certain vehicles from the 2024 and 2025 model years may have improperly installed components that could come into contact with the cooling fan assembly, creating an electrical short.

In the affected vehicles, the starter motor’s protective cover may not be fully seated over the B+ terminal, which is the main connection where power from the car’s battery flows in to help start the engine.

According to the manufacturer, if the cover is not properly in place, the exposed terminal could touch nearby metal parts, causing an electrical short and increasing the risk of a fire, which could lead to severe injuries or even death if an individual does not exit the vehicle in time.

In November 2024, Hyundai detected smoke in the engine compartment of a Santa Fe vehicle during a post-test inspection, indicating signs of a thermal event. However, the recall chronology report (PDF) does not currently list any field incidents, crashes or injuries related to the issue. 

After reviewing the test results, Hyundai initiated a field investigation earlier this year, which discovered numerous vehicles with partial or no coverage of the B+ terminal.

The manufacturer eventually determined that properly installed terminal covers remained securely in place in the vehicles and did not cause a short circuit during testing. However, it is possible that not all covers were properly installed.

As a result of these findings, Hyundai decided to conduct a voluntary safety recall (PDF) on September 25, for 135,386 model year 2024 and 2025 Hyundai Santa Fe vehicles.

Customer notification letters will begin mailing on December 1, which will include instructions on how to receive a free inspection and, if necessary, reinstallation of the starter motor assembly at a local Hyundai dealer.

Hyundai’s number for this recall is 285. Customers may contact Hyundai customer service at 1-855-371-9460 or the manufacturer’s contact for the recall, Emily Smith, by email at emily.c.smith@dot.gov.

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-275-9171), or go to www.nhtsa.gov.

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