2021 Hyundai Kona Electric problems

POWER TRAIN

On February 3, 2026, while driving in a high-traffic turning lane, my Hyundai Kona Electric vehicle suddenly lost propulsion and would not accelerate. The vehicle shut down without warning and could not be restarted. Traffic was building behind me, creating a safety hazard. I felt unsafe due to surrounding vehicles expecting movement, I contacted the police for assistance. The vehicle had to be towed from the roadway. The vehicle was transferred between 3 dealerships before being diagonsed. On February 16, 2026, the issue was diagnosed as a motor position sensor failure affecting the propulsion system. The vehicle has remained inoperable since February 3, 2026, and there is no repair ETA due to parts availability. The vehicle remains at the servicing dealership and is available for inspection upon request. There were no prior warning lamps, dashboard messages, or noticeable symptoms before the sudden loss of propulsion. This incident involved a sudden failure of the vehicle’s propulsion system while operating in active traffic and presented a significant safety concern.

NHTSA complaint #11719765 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

On February 3, 2026, while driving in a high-traffic turning lane, my Hyundai Kona Electric vehicle suddenly lost propulsion and would not accelerate. The vehicle shut down without warning and could not be restarted. Traffic was building behind me, creating a safety hazard. I felt unsafe due to surrounding vehicles expecting movement, I contacted the police for assistance. The vehicle had to be towed from the roadway. The vehicle was transferred between 3 dealerships before being diagonsed. On February 16, 2026, the issue was diagnosed as a motor position sensor failure affecting the propulsion system. The vehicle has remained inoperable since February 3, 2026, and there is no repair ETA due to parts availability. The vehicle remains at the servicing dealership and is available for inspection upon request. There were no prior warning lamps, dashboard messages, or noticeable symptoms before the sudden loss of propulsion. This incident involved a sudden failure of the vehicle’s propulsion system while operating in active traffic and presented a significant safety concern.

NHTSA complaint #11719765 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

File with NHTSA now please!!!! What do you have to lose??? If anything If they do an investigation we are safe post warranty. Report a Vehicle Safety Problem, Equipment Issue | NHTSA [XXX] The Hyundai Kona Electric Vehicle (EV) has experienced issues with its Integrated Charging Control Unit (ICCU) due to problems with the low-conductivity coolant (BSC-1) used in models produced between 2018 and October 2021. This coolant can crystallize, forming debris that clogs the cooling system, leading to false "Refill Inverter Coolant" warnings and potential overheating risks. A Technical Service Bulletin (TSB 23-01-049H) outlines a recall to flush and replace the coolant with an improved BSC-2 formula to address this issue. However, improper or repeated coolant flushes, if not performed correctly using Hyundai’s specialized equipment and procedures, can leave air bubbles or residual debris in the system, which may impair cooling efficiency and stress critical components like the ICCU, inverter, and electric motor. Repeated coolant flushes, especially when not executed properly, can exacerbate issues by introducing air locks or failing to fully remove crystallized debris, potentially causing damage to the ICCU, inverter, and motor. Air bubbles trapped in the cooling system can reduce heat dissipation, leading to overheating that may degrade the ICCU’s electronics or cause the inverter and motor to operate at unsafe temperatures, risking premature failure. Posts on forums indicate that some vehicles required multiple flushes to clear the warning, with improper flushing sometimes leaving contaminants that continue to trigger sensors or obstruct coolant flow. This underscores the importance of having the procedure done by trained technicians using the correct tools to avoid long-term damage to these sensitive components. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11683954 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

Potential Fire and safety risk ... The Hyundai Kona Electric Vehicle (EV) has experienced issues with its Integrated Charging Control Unit (ICCU) due to problems with the low-conductivity coolant (BSC-1) used in models produced between 2018 and October 2021. This coolant can crystallize, forming debris that clogs the cooling system, leading to false "Refill Inverter Coolant" warnings and potential overheating risks. A Technical Service Bulletin (TSB 23-01-049H) outlines a recall to flush and replace the coolant with an improved BSC-2 formula to address this issue. However, improper or repeated coolant flushes, if not performed correctly using Hyundai’s specialized equipment and procedures, can leave air bubbles or residual debris in the system, which may impair cooling efficiency and stress critical components like the ICCU, inverter, and electric motor. Repeated coolant flushes, especially when not executed properly, can exacerbate issues by introducing air locks or failing to fully remove crystallized debris, potentially causing damage to the ICCU, inverter, and motor. Air bubbles trapped in the cooling system can reduce heat dissipation, leading to overheating that may degrade the ICCU’s electronics or cause the inverter and motor to operate at unsafe temperatures, risking premature failure. Posts on forums indicate that some vehicles required multiple flushes to clear the warning, with improper flushing sometimes leaving contaminants that continue to trigger sensors or obstruct coolant flow. This underscores the importance of having the procedure done by trained technicians using the correct tools to avoid long-term damage to these sensitive components.

NHTSA complaint #11683955 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

Manufacturing defect ... Took it in 4 times for "refill inverter coolant" warning . They had a campaign ' tried by couldn't get the light to go away . It was their first time ever performing this on an EV at Kerry hyundai alexandria . Now TD EV in mason Ohio is confirming my inverter failed as a direct result of the poor flushes and poor manufacturing. I am seeking for hyundai to cover all related costs. I haven't had my vehicle for over a month . It's out of warranty 'however this was a known issue they issued a campaign for 'and then couldn't fix the issue after 4 or 5 tries and 2 different hyundia dealers . All work performed will be listed at Kerry hounding in alexandria KY and Jefferson wyler hyundai cincinnati Ohio.

NHTSA complaint #11677951 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

Hyundia has had my car in for the SAME recall 4 to 5 times . 6 total weeks this time around. The ""refill inverter coolant" light kept coming back on . The last time I got it home it had more issues than when I took it in and wouldn't even catch a charge . (EV) They fried my compassitor trying to fix the inverter coolant recall . I then took had to pay 450 for a diagnostic ' (Kerry hyundai alexandria) They said electric motor is bad and will cost 8000 to 9000. Got a 2nd diagnostic (Jeff wyler hyundai cincinnati) Completely different result- Zero mention of motor ' said Ac compasitor failed. (Had no issues prior to them working on the original recall ) The light for the recall is still on by the way and they want me to pay 3500 for new AC capacitor . (600 diagnostic included in that price ) " The dealership’s failure to properly perform the inverter coolant refill recall directly caused the AC compressor failure in my 2021 Hyundai Kona EV. Before taking the vehicle in for the recall, the AC system was fully functional, delivering cold air without any issues, and the car experienced no charging problems, indicating the battery and cooling systems were operating normally. The recall, intended to flush the inverter cooling system and replace the crystallizing BSC-1 coolant with BSC-2, was not completed correctly, as evidenced by the dealership’s admission that they couldn’t fix it. This botched service likely left air or debris in the cooling system, which, in Kona EVs with a heat pump, could overwork the AC compressor used for battery cooling during charging. The compressor’s failure shortly after the recall service, despite no prior issues, strongly suggests that the improper coolant flush caused undue stress on the compressor, leading to its $3,000 failure, which should be covered under warranty or as a goodwill repair due to the dealership’s error". [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11674690 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

The car was unable to charge using level 3 DC fast chargers, necessitating the use of a level 2 charger for an extended length of time in order to be able to return home. A Hyundai dealer replaced the charging inlet lock actuator (invoice attached).

NHTSA complaint #11669567 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The car was unable to charge using level 3 DC fast chargers, necessitating the use of a level 2 charger for an extended length of time in order to be able to return home. A Hyundai dealer replaced the charging inlet lock actuator (invoice attached).

NHTSA complaint #11669567 — an unverified report by a vehicle owner.

SERVICE BRAKES

After powering on the car, the dashboard displayed multiple brake system warnings, including the brake system warning light and a message on the LCD display that read "Check regenerative brakes." A Hyundai dealer replaced the integrated electric brake unit assembly (invoice attached).

NHTSA complaint #11669350 — an unverified report by a vehicle owner.

ENGINE

Fill coolant warning came on, we checked the coolant and the coolant level was good. I spoke to a Hyundai service center and the rep said that sometimes this happens with Hyundais and it may go off. Indeed it did but then Fill coolant warning came back and the coolant level was still good. After several weeks of the Fill Coolant warning being on more often than not, the car started one morning but couldn’t be driven as the handbrake was stuck on, the fill coolant warning was on and the tire pressure warning was on, (even though the tire pressure on all tires was ok) I guess this was the EVs way of saying “Do Not Drive Me”. We got the car to the dealership, they performed a scan and found no codes. They preformed a total coolant flush as per Service Campaign T9E. This service was performed on 21 April, 2025 and thus far the fill coolant light has stated off. We bought this car used just 2 months prior and found through previous maintenance history that this EV had this service Campaign T9E done in January 2024. Our concern with this issue is two fold, 1) My wife could have been anywhere when the car went into: Don’t drive me mode. 2) is this going to be an annual event, which will cost several hundred dollars to address each time when this may no longer be covered by warranty

NHTSA complaint #11657178 — an unverified report by a vehicle owner.

BACK OVER PREVENTION

The contact owns a 2021 Hyundai Kona Electric. The contact stated while the vehicle was parked, the rearview camera became inoperable. The contact stated that the image on the rearview camera went blank. There was no warning light illuminated. The vehicle was taken to the dealer, and it was diagnosed and determined that the tailgate wiring harness had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and offered to pay for 60 percent of the parts and labor cost to repair the vehicle. The contact declined the offer provided by the manufacturer. The approximate failure mileage was 86,612.

NHTSA complaint #11630575 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

My vehicle has said, refill inverter coolant, I took it in a couple of days ago and they said there is an open recall and they would fix it. They called me back after I dropped it off and informed me that they did not have the specific coolant, and no one in the area did. Over the past couple days, my vehicle has had issues turning on.

NHTSA complaint #11586833 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM:12V/24V/48V BATTERY

The contact owns a 2021 Hyundai Kona Electric. The contact stated that the battery had discharged. The contact stated that the 12-volt battery and “Bring in for Service, and key not detected messages were displayed. The contact stated that while his mother was driving at an undisclosed speed, the vehicle stalled on two occasions. The vehicle flickered, and the vanity lights dimmed and flickered. The contact called the local dealer, where the vehicle was rebooted. The contact stated that five attempts were needed to unlock the parking brake. The tow truck mechanic informed the driver that the 12-volt battery was not registering. The vehicle was towed to the local dealer, who was unable to duplicate the failure. The vehicle was not repaired. The manufacturer was contacted, and no assistance was provided. The failure mileage was approximately 38,000.

NHTSA complaint #11541418 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2021 Hyundai Kona Electric. The contact stated that the battery had discharged. The contact stated that the 12-volt battery and “Bring in for Service, and key not detected messages were displayed. The contact stated that while his mother was driving at an undisclosed speed, the vehicle stalled on two occasions. The vehicle flickered, and the vanity lights dimmed and flickered. The contact called the local dealer, where the vehicle was rebooted. The contact stated that five attempts were needed to unlock the parking brake. The tow truck mechanic informed the driver that the 12-volt battery was not registering. The vehicle was towed to the local dealer, who was unable to duplicate the failure. The vehicle was not repaired. The manufacturer was contacted, and no assistance was provided. The failure mileage was approximately 38,000.

NHTSA complaint #11541418 — an unverified report by a vehicle owner.

VEHICLE SPEED CONTROL

While driving on the highway at 70 mph, cruise control engaged, there was a sudden loss of drive power. I could not accelerate, or return to the cruising speed. The speed just dramatically fell. The only remedy was to pull over to the side of the road, turn off the car, and start it again. This VIN was not included in the initial similar recall earlier this year.

NHTSA complaint #11541136 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

The contact owns a 2021 Hyundai Kona Electric. The contact received notification of NHTSA Campaign Number: 22V941000 (Electrical System) however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA complaint #11508764 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

July of 2022, vehicle went in due to battery not charging. Vehicle kept at Temecula Hyundai repair until September 2022 for EV battery replacement. Upon return, EV battery still didn't change. September 2022 vehicle went back for repairs. Returned October 2022. Was told battery overheating sensor was faulty and was turned off. As a result the EV battery will not be able to charge beyond 90%. Was told nothing else they could do to repair the car. When I asked if there was an increased risk of battery getting too hot, the response was " their should not be". My concern is that their going to be an overheating issue while the vehicle is changing at my home. Contacted Hyundai about it; they did an investigation and determined there was reason for them to buy back the vehicle. They offered to buy it back at less that what the buy out the finance company states. It is now February 2023. Hyundai still has yet to buy back the vehicle at what is owed on it, and still have no idea how to due the proper repairs. They still cannot assure that the battery won't overheat and there are no sensors to notify if it does.

NHTSA complaint #11504717 — an unverified report by a vehicle owner.

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

After just 18 months and about 5,000 miles, the heater/defroster system stopped working. My local Hyundai dealer (Dick Hannah Volkswagen/Hyundai) confirmed the failure. Even after installing a new heater unit, the dealer reported the system is still not working. My car has been at the dealer since 1-17-23. Having no defroster is a serious safety issue in the winter here in Portland, Oregon, as the car can become unsafe to drive when the windows fog-up (as is common in the winter here). There were no warning lights or notifications to indicate that anything had failed; I just noticed that heat was not coming on, and only cold air was blowing through the defroster vents.

NHTSA complaint #11504227 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

After just 18 months and about 5,000 miles, the heater/defroster system stopped working. My local Hyundai dealer (Dick Hannah Volkswagen/Hyundai) confirmed the failure. Even after installing a new heater unit, the dealer reported the system is still not working. My car has been at the dealer since 1-17-23. Having no defroster is a serious safety issue in the winter here in Portland, Oregon, as the car can become unsafe to drive when the windows fog-up (as is common in the winter here). There were no warning lights or notifications to indicate that anything had failed; I just noticed that heat was not coming on, and only cold air was blowing through the defroster vents.

NHTSA complaint #11504227 — an unverified report by a vehicle owner.

EXTERIOR LIGHTING

The headlights even though they are LED they have a terrible beam pattern with noticeable dark spots in your field of view. Also I get flashed from oncoming traffic because of the low mounting position of the head lights easily blinds on coming traffic with the slightest bump or incline in the road. I had the dealer check out their alignment and was told they are fine. I myself have been dazzled by other Kona’s coming at me. I feel these lights are an issue and I see more and more cars with these low mounted headlights which I feel is a design issue that needs to be addressed due to the angle the lights need to shine they easily dazzle oncoming traffic.

NHTSA complaint #11497674 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

My 2021 Hyundai Kona EV battery need to be replaced. But the dealer would not have estimated time when my Kona EV get new battery. It could take 1 month or 3 months. No clues. I would not make a mistake to buy another car like Hyundai EV.

NHTSA complaint #11486128 — an unverified report by a vehicle owner.

ENGINE

My 2021 Hyundai Kona EV battery need to be replaced. But the dealer would not have estimated time when my Kona EV get new battery. It could take 1 month or 3 months. No clues. I would not make a mistake to buy another car like Hyundai EV.

NHTSA complaint #11486128 — an unverified report by a vehicle owner.