Hyundai is recalling more than 135,000 Santa Fe SUVs due to a manufacturing defect that could cause an electrical fire in certain crashes, affecting 2024 and 2025 model year Santa Fe vehicles equipped with 2.5-liter turbocharged engines built between December 28, 2023, and July 7, 2025.
The starter motor’s protective cover may not have been fully installed during assembly at Hyundai’s Alabama manufacturing plant. If the terminal is exposed and the vehicle is in a crash damaging the engine compartment, the exposed part could contact the cooling fan and create an electrical short, increasing fire risk.
The automaker will notify owners by mail starting December 1. Dealers will inspect vehicles and properly install the terminal cover if needed, free of charge. Hyundai estimates only 1% of recalled vehicles actually have the defect.
The problem came to light after a November 2024 safety crash test conducted by the National Highway Traffic Safety Administration. Smoke was detected in the engine compartment after the test, prompting an investigation.
As of October 2, Hyundai reported no crashes, injuries, or deaths related to this issue in regular use, only the single crash test incident.
Santa Fe owners can check if their vehicle is affected by visiting NHTSA.gov/recalls and entering their vehicle identification number (VIN). Owners with questions can contact Hyundai customer service at 1-855-371-9460 and reference recall number 285. The NHTSA recall number is 25V-659.
The repair will be free regardless of warranty status. Hyundai will also reimburse owners for any out-of-pocket expenses already incurred to fix this issue.
The recall affects a popular SUV model during a period when automotive manufacturers face increasing scrutiny over vehicle safety and manufacturing quality control. The Alabama plant where the defect occurred produces vehicles for the North American market.
