Hyundai recalls Santa Fe SUVs in the United States after identifying a safety defect that could increase the risk of engine compartment fires in certain crash scenarios. This major recall affects more than 135,000 vehicles and shines a spotlight on both Hyundai’s recent safety challenges and the long history of Santa Fe recalls that have shaped the model’s reputation over time.
This in-depth article breaks down the latest recall, explores past recall trends, explains the technical mechanics behind the defect, and provides a clear guide for Santa Fe owners on what to do next.
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Latest Hyundai Recalls Santa Fe Action: What’s Happening Now
Hyundai has issued a recall covering 135,386 non-hybrid Santa Fe SUVs from the 2024 and 2025 model years. The issue involves the starter motor’s “B+” terminal cover, which may not have been properly seated during assembly. In the event of a crash, deformation of the engine bay could cause the exposed terminal to make contact with surrounding components like the cooling fan, creating a short circuit and potentially leading to a fire.
The defect came to light during crash testing when smoke was observed in the engine compartment of a 2024 Santa Fe. Although Hyundai has not documented any real-world fires linked to this issue, the company decided to issue a recall to address the problem before any incidents occur.
This recall applies specifically to Santa Fe models equipped with the turbocharged 2.5-liter gasoline engine. Hybrid models are not affected.
Key facts about the recall:
- Vehicles affected: 135,386 units in the U.S.
- Model years: 2024 and 2025 non-hybrid Santa Fe
- Notification period: Begins December 1, 2025
- Repair: Inspect and reseat the starter motor cover
- Cost to owners: $0 (fully covered by Hyundai)
- Estimated repair time: 30 minutes or less
Hyundai dealers will inspect the starter motor cover during the recall service and ensure it’s correctly positioned. If needed, the cover will be reseated or replaced free of charge. Until repairs are completed, owners are advised to stay alert for any unusual electrical activity or smoke from the engine bay.
How to Check if Your Santa Fe Is Affected
Santa Fe owners can confirm whether their vehicle is part of this recall by checking their VIN (Vehicle Identification Number). Hyundai will mail official recall notifications starting in December, but owners don’t have to wait — they can check using Hyundai’s recall lookup tools or by contacting a dealership directly.
Once a vehicle is identified as part of the recall:
- Owners will receive a letter with instructions on how to schedule an appointment.
- Dealerships will perform the inspection and repair at no cost.
- The process takes less than an hour in most cases.
While Hyundai states the risk is low unless a crash occurs, any unusual signs such as burning smells or smoke should prompt immediate service.
Santa Fe Recall History: A Legacy of Safety Campaigns
The Santa Fe has long been a popular SUV in the U.S., but its history is also marked by multiple recall campaigns covering mechanical, electrical, and software issues. Understanding this background helps put the current recall into perspective.
Engine and Bearing Issues (2013–2014)
Earlier Santa Fe models experienced problems with improperly machined engine components that caused premature bearing wear. These recalls involved engine inspections and, in some cases, full replacements to prevent engine failure and fire risks.
ABS Module and Fire Risks (2016–2018)
Several recalls were issued to address potential internal leaks in ABS modules that could cause short circuits and fires, even when the vehicle was parked. Owners were advised to park outside and away from structures until repairs were completed.
Rearview Camera Failures (2021–2022)
Hyundai recalled a large number of Santa Fe units due to faulty solder joints that caused rearview cameras to fail. This affected driver visibility and pedestrian safety, prompting a significant recall.
Turbocharger Oil Leaks (2022)
Santa Fe models equipped with turbocharged engines were recalled because oil supply pipes could crack and leak near hot components, creating a fire hazard.
Valve Cover and Alternator Oil Leaks (2007–2009)
Older Santa Fe generations were subject to campaigns to address valve cover gasket leaks that dripped oil onto alternators, potentially causing electrical failures and fires.
Loose Engine Bolts (2025–2026)
In a separate recent recall, a small number of 2025–2026 Santa Fe and Tucson SUVs were recalled due to improperly torqued engine rod bolts that could cause power loss or leaks.
These past issues reveal a consistent pattern: while Hyundai has acted to address defects through recalls, Santa Fe owners have had to remain vigilant over time to ensure safety issues are resolved.
Technical Breakdown: Why the Starter Motor Cover Matters
To understand the current recall fully, it’s important to look at the starter motor and the B+ terminal itself.
- Starter motor: The device that turns the engine over during startup, drawing high current directly from the battery.
- B+ terminal: The primary positive electrical connection to the battery, carrying full system voltage.
If the protective cover over this terminal is not fully seated, the terminal can be exposed. Under normal conditions, this might not cause any problems. However, during a crash, parts of the engine bay can shift, bend, or deform. If the exposed terminal contacts nearby conductive components like the cooling fan housing, it can create a direct short circuit.
Short circuits at this point in the electrical system generate intense heat quickly. That heat can ignite surrounding plastic or insulation, leading to engine compartment fires.
This is why the issue is categorized as a fire risk, even though no real-world fires have been reported. Crash test smoke was enough to trigger a formal recall because U.S. safety regulations require automakers to act on any defect that could increase the risk of fire or injury.
Step-by-Step Recall Process for Hyundai Santa Fe Owners
Here’s how the recall process will unfold for this campaign:
- Defect Identification
Hyundai identified the issue during testing and filed a recall report. - Regulatory Notification
The company notified U.S. safety authorities, triggering the formal recall process. - Owner Notification
Hyundai will mail letters to affected owners starting in December 2025. - Dealer Preparation
Hyundai dealerships receive repair instructions and any necessary parts to carry out the fix. - Inspections and Repairs
Owners bring vehicles in for inspection and reseating of the starter motor cover. - Completion Reporting
Hyundai tracks and reports repair completion rates to ensure compliance.
For owners, the process is simple and free. However, prompt action is essential to ensure vehicle safety and compliance with recall requirements.
Why This Recall Matters for U.S. SUV Owners
SUVs like the Santa Fe are commonly used for family transportation, road trips, and daily commuting. Recalls affecting fire risk are taken seriously in the U.S. because of their potential to cause injury and property damage.
This recall also reinforces the complexity of modern vehicles. With dense packaging and high electrical loads, even a small misalignment like a partially seated cover can create a significant safety hazard in rare situations.
For Hyundai, the recall highlights ongoing quality control challenges and the need to maintain consumer trust after multiple recall campaigns over the past decade.
What Santa Fe Owners Should Do Now
If you own a 2024 or 2025 non-hybrid Santa Fe, here’s what you should do:
- Check your VIN to see if your vehicle is included in the recall.
- Watch for your letter starting in December.
- Schedule your appointment promptly for a quick, free inspection and fix.
- Be alert for warning signs like burning smells or smoke and act immediately if they appear.
- Keep documentation of the repair for your records.
Timely action ensures your vehicle remains safe and compliant with federal safety standards.
Looking Ahead
Once repairs are underway, Hyundai will monitor completion rates and the effectiveness of the fix. The company will also watch for any real-world incidents that might require further action. For owners, staying informed and proactive remains the best strategy.
The Hyundai recalls Santa Fe campaign isn’t just another service notice—it’s part of a broader safety picture that affects one of the country’s most popular SUVs. If your vehicle is part of this recall, acting quickly ensures peace of mind and protects everyone on the road.
Have you received your recall notice yet or had your vehicle inspected? Share your experience or questions below to help other Santa Fe owners stay informed.
