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Hyundai recalls 135,000 Santa Fe SUVs due to fire hazard
Hyundai is recalling over 135,000 Santa Fe SUVs due to a manufacturing defect that could lead to an electrical fire in certain crash scenarios.
The recall covers 2024 and 2025 model year Santa Fe vehicles with 2.5-liter turbocharged engines, produced between Dec. 28, 2023, and July 7, 2025, at Hyundai’s Alabama assembly plant. The issue involves the starter motor’s protective cover, which may not have been fully installed during assembly. If the terminal is exposed and the engine compartment is damaged in a crash, it could contact the cooling fan, creating an electrical short and increasing the risk of fire. Hyundai estimates that only about 1% of affected vehicles actually have the defect.
The defect was discovered after a November 2024 NHTSA crash test revealed smoke in the engine compartment, prompting an investigation. As of Oct. 2, Hyundai reported no crashes, injuries, or deaths related to the issue outside of the test.
Owners will be notified by mail starting Dec. 1. Dealers will inspect the vehicles and install the terminal cover if necessary at no cost. Hyundai will also reimburse any owners who have already paid to fix the issue. Santa Fe owners can check if their vehicle is affected by entering their VIN at NHTSA.gov/recalls. For questions, owners can contact Hyundai customer service at 1-855-371-9460, referencing recall number 285 (NHTSA recall number 25V-659).
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