Hyundai Motor announced the recall of 135,386 Santa Fe vehicles in the United States due to a fire risk caused by improper starter motor installation. The issue affects 2024 and 2025 models, manufactured between December 28, 2023, and July 7, 2025. The National Highway Traffic Safety Administration (NHTSA) identified that the positive B+ terminal cover may become loose and contact the cooling fan blade.
This failure increases the chance of an electrical short circuit during a collision, which could result in a fire. There are no confirmed incident reports at this time. The manufacturer estimates that only 1% of the affected vehicles exhibit the defect.
Owners will be notified starting December 1, 2025, to take their cars to authorized dealerships.
Details of the starter motor defect
The starter motor in question equips the non-hybrid Santa Fe models, all with a 2.5-liter turbocharged four-cylinder engine. The protective cover for the main electrical terminal, known as B+, may not be properly secured during factory assembly.
This irregularity occurs when the cover does not fully seat on the terminal, exposing wires and components to intense vibrations in accidents. NHTSA tests confirmed that contact with the fan blade causes sparks and potential ignition of nearby materials.
Inspection and repair procedures
Hyundai dealerships will perform a free inspection of the starter motor on all recalled vehicles. If the cover is improperly installed, technicians will remove and reinstall the component with the appropriate torque.
The process takes about 30 minutes and does not require prior scheduling at many service centers. Owners can check the NHTSA website using the vehicle identification number (VIN) to confirm if their car is on the list.
The manufacturer emphasizes that the vehicles remain safe for daily use until the repair, as long as they are parked away from flammable structures.
Affected models and recall history
The involved Santa Fe vehicles are exclusively the conventional versions, excluding hybrids and plug-ins. Total production of the 2024-2025 models exceeds 200,000 units in the US, making the recall significant for the lineup.
- Manufactured in Hyundai factories in South Korea and Alabama.
- Equipped with an eight-speed automatic transmission.
- Sold at authorized dealerships since early 2024.
Hyundai records annual recalls to maintain safety standards, with a focus on electrical systems.
Impact on production and supply chain
The starter motor failure reflects challenges on the assembly line, where automation does not always detect manual errors. Korean suppliers of electrical components, such as Mobis, are adjusting protocols to prevent repetitions in future shipments.
US dealerships are preparing extra stocks of replacement covers to minimize delays. The NHTSA monitors the correction to ensure full compliance by the end of 2026.
This action demonstrates the manufacturer’s commitment to transparency, especially in regulated markets like the American one.
Preventive measures for owners
Santa Fe owners should check the recall status on the NHTSA portal immediately. Avoid driving in high-risk conditions, such as steep roads, until the inspection.
- Monitor dashboard signs of overheating.
- Park in open areas if you notice a burning smell.
- Contact Hyundai via the 24-hour support phone line.
These guidelines reduce unnecessary concerns during the notification period.
NHTSA regulatory context
The US federal agency requires mandatory recalls for defects that compromise vehicle safety. In 2024, it processed over 1,000 similar actions, covering millions of units from various brands.
Hyundai’s initial investigations, started in September 2025, confirmed the issue in factory samples. Final reports include diagrams of the electrical system to assist mechanics.
Compliance avoids fines and strengthens the South Korean manufacturer’s global reputation.
Expansion to other markets
Although the recall is exclusive to the US, European and Asian authorities are assessing impacts on exports. Hyundai plans internal audits at all production plants.
Santa Fe versions sold in Brazil, imported from Korea, may receive similar updates if defects are detected locally. Anfavea monitors imports to align standards.
This proactivity prevents cascading recalls and maintains international consumer trust.
