Hyundai Recalling The Santa Fe Because It Could Catch Fire If Crashed
Hyundai is recalling 135,000 Santa Fes from 2024 and 2025 model years after a U.S. government crash test revealed a potential fire risk linked to the starter motor assembly.
Key Points
- Hyundai found that some vehicles may have partially uncovered starter terminals, which could contact the cooling fan housing under impact.
- Tests confirmed that the defect only occurs if the terminal cover is incorrectly installed.
- Hyundai is recalling affected 2024–2025 Santa Fe models for inspection and reinstallation of the terminal cover, free of charge.
The automaker confirmed that the defect could cause an electrical short under certain crash conditions, prompting a recall after a months-long joint investigation between Hyundai engineers and the National Highway Traffic Safety Administration (NHTSA).
The issue first surfaced after an NHTSA New Car Assessment Program (NCAP) front-barrier crash test involving a 2024 Hyundai Santa Fe. Inspectors observed smoke rising from the engine bay during post-test analysis, indicating thermal damage. Hyundai’s technical teams at the Hyundai Automotive Technical Center (HATCI) and Hyundai Motor Company (HMC) immediately began investigating.
Engineers determined that the vehicle’s starter motor terminal cover might not have been properly seated during assembly. If the cover isn’t fully installed, the exposed “B+” terminal on the starter could come into contact with the cooling fan assembly during a collision—creating a direct electrical short which could potentially spark a fire.
According to Hyundai, there have been no field incidents, crashes, injuries, or fatalities linked to the issue—only the single NCAP test result that revealed signs of a thermal event.
Owners of affected 2024–2025 Santa Fe models will receive recall notices by mail beginning later this fall. Dealers will inspect and, if necessary, reinstall the starter motor terminal cover at no cost.
This article was co-written using AI and was then heavily edited and optimized by our editorial team.
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