According to the recall announcement from the National Highway Traffic Safety Administration (NHTSA), Hyundai Motor will recall more than 1.6 million vehicles in the United States. Since 2017, Hyundai vehicles have been involved in 21 car fires and 22 overheating incidents in the United States.
On September 22, Hyundai recalled 1,642,551 vehicles in the United States with an estimated defect percentage of 1%, according to the recall announcement.
In the summer of 2019, Hyundai was informed of ABS module overheating issues in U.S.-market Elantra and Accent models and obtained the modules for inspection, but both were severely damaged and could not determine the cause of the problem.
Hyundai Motor North America Safety Operations has opened three cases and was informed of a fourth case involving the Elantra in December 2020 and opened an investigation into the issue. That vehicle’s modules were also sent for inspection.
Hyundai first discovered the cause of the problem in February 2021, finding evidence of a brake fluid leak within the unit.
Reports of car troubles continued throughout 2021, and Hyundai hired a third-party engineering firm called Exponent to see if the root cause could be determined.
By December 2021, Exponent told Hyundai that the overheating issue could be caused by an internal leak of brake fluid in the ABS module’s hydraulic circuit. Research into the faulty module continued and in May 2022 the culprit was identified – brake fluid on both sides of the O-ring on the ABS motor shaft.
The investigation continues into 2022 and 2023, and Hyundai found foreign material contaminants in brake fluid remaining in the modules. Then, this summer, the company finally identified the ultimate cause:
Exponent discovered that the O-rings used in ABS modules are composed of different rubber material formulations determined through thermogravimetric (“TGA”) analysis. In an update provided on September 6, 2023, Exponent confirmed that certain material formulations used in O-ring rubber may age and lose hardness over time. Additionally, the material may be affected by foreign contaminants in the brake fluid, which may affect sealing performance.Hyundai said owners of affected cars can continue to drive them, but they should park their vehicles outside and away from buildings until the problem is resolved. The remedy is to use a new ABS module fuse that provides less operating current to the module. Hyundai also said that “owners of affected vehicles will be reimbursed for out-of-pocket costs incurred to obtain remedies for the recall conditions in accordance with a reimbursement plan submitted to NHTSA on February 24, 2022.”
Attached are the recalled models:
2012-2015 Hyundai Accent
2012-2015 Hyundai Yazun
2011-2015 Hyundai Elantra
2013-2015 Hyundai Elantra Coupe
2014-2015 Hyundai Equus
2011-2015 Hyundai Genesis Coupe
2013-2015 Hyundai Santa Fe
2013-2013 Hyundai Santa Fe Sport
2010-2013 Hyundai Tucson
2015-2015 Hyundai Tucson Fuel Cell Vehicle
2011-2015 Hyundai Sonata Hybrid
2012-2015 Hyundai Veloster
2010-2012 Hyundai Veracruz