2020 Hyundai Sonata problems

ELECTRICAL SYSTEM

A/C blower motor fan would stop working. Happened twice within less than a year apart. Upon further inspection, multi fuse wiring overheated and melted, ruining fuse and making A/C stop working during 100+ temperatures outside. Apparently this is a well known issue with this make and model Sonata. Electrical failure.

NHTSA complaint #11762639 — an unverified report by a vehicle owner.

POWER TRAIN

I am submitting a safety complaint regarding a recurring, unresolved electrical defect in my 2020 Hyundai Sonata SEL. The vehicle fails to recognize when the ignition is switched off, leaving core vehicle systems active and causing severe parasitic battery drain that leaves the car immobilized. ​Description of the Problem: ​False "On" Status: After parking, turning off the engine, and exiting the vehicle, the car continues to register as though the ignition is still active/on (accessories, cluster, or vehicle network remain awake). ​ Severe Parasitic Draw: Because the vehicle fails to shut down its electrical circuits, the 12-volt battery repeatedly discharges overnight or while parked for short durations. ​Battery Replacement Did Not Resolve Issue: The 12-volt battery was replaced with a brand-new unit to eliminate typical wear, yet the drain and false "on" behavior persisted immediately. ​ Frequency: The vehicle frequently fails to start, requiring constant jump-starts or roadside assistance to operate. ​Safety Hazard: This defect creates a direct safety risk by repeatedly stranding the driver without warning in public locations, traffic stops, or remote areas. In addition, an electrical system that fails to enter a sleep state creates a potential hazard for component overheating, failure of electronic security and locking systems, or total electrical failure while attempting to restart or operate auxiliary safety equipment. Other Hyundai owners have reported identical issues where the body control modules or ignition logic fail to power down. ​Corrective Action Requested: I request that the NHTSA investigate this electrical shutdown defect across the 2020 Hyundai Sonata model year to identify whether a faulty Body Control Module (BCM), smart key receiver, or ignition switch relay requires a safety recall and software or hardware remediation. Battery replaced on 09/04/2026 Car inspected/diagnosed by Hyundai Dealership on 09/03/2026

NHTSA complaint #11761900 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

I am submitting a safety complaint regarding a recurring, unresolved electrical defect in my 2020 Hyundai Sonata SEL. The vehicle fails to recognize when the ignition is switched off, leaving core vehicle systems active and causing severe parasitic battery drain that leaves the car immobilized. ​Description of the Problem: ​False "On" Status: After parking, turning off the engine, and exiting the vehicle, the car continues to register as though the ignition is still active/on (accessories, cluster, or vehicle network remain awake). ​ Severe Parasitic Draw: Because the vehicle fails to shut down its electrical circuits, the 12-volt battery repeatedly discharges overnight or while parked for short durations. ​Battery Replacement Did Not Resolve Issue: The 12-volt battery was replaced with a brand-new unit to eliminate typical wear, yet the drain and false "on" behavior persisted immediately. ​ Frequency: The vehicle frequently fails to start, requiring constant jump-starts or roadside assistance to operate. ​Safety Hazard: This defect creates a direct safety risk by repeatedly stranding the driver without warning in public locations, traffic stops, or remote areas. In addition, an electrical system that fails to enter a sleep state creates a potential hazard for component overheating, failure of electronic security and locking systems, or total electrical failure while attempting to restart or operate auxiliary safety equipment. Other Hyundai owners have reported identical issues where the body control modules or ignition logic fail to power down. ​Corrective Action Requested: I request that the NHTSA investigate this electrical shutdown defect across the 2020 Hyundai Sonata model year to identify whether a faulty Body Control Module (BCM), smart key receiver, or ignition switch relay requires a safety recall and software or hardware remediation. Battery replaced on 09/04/2026 Car inspected/diagnosed by Hyundai Dealership on 09/03/2026

NHTSA complaint #11761900 — an unverified report by a vehicle owner.

ENGINE

The A/C evaporator core and the core seal needs replacing on 2020 Hyundai Sonata. Car is 6 years old. I already have a confirmed diagnosis with a PPM refrigerant leak tester at the condensate drain line The diagnosis is 100% confirmed. The evaporator is leaking heavily—we pulled 274 PPM at the drain tube and 177 PPM inside the cabin behind the glove box so refrigerent has been leaking out of the vents. My wife and I were getting headaches for no reason. Our AC has failed and this problem was discovered as the issue and I am paying out of pocket to fix something that should not have failed and has leaked out refrigerent.

NHTSA complaint #11761990 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

Blower motor malfunction at night. Smelled something burning. Extremely hot and humid outside. Windows fogged up inside which greatly reduced visibility. Checked the multifuse which controls the ABS, oil pump, cooling fan, & Blower. I discovered a burnt connection on one of the terminals for the blower. This is a huge safety and fire risk and needs to be addressed ASAP!!!! Upon my research, I’m finding several Hyundai Sonata vehicles having this same exact issue. Kia vehicles are being recalled for this same exact issue. Why isn’t the Hyundai Sonata??

NHTSA complaint #11758874 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

Blower motor malfunction at night. Smelled something burning. Extremely hot and humid outside. Windows fogged up inside which greatly reduced visibility. Checked the multifuse which controls the ABS, oil pump, cooling fan, & Blower. I discovered a burnt connection on one of the terminals for the blower. This is a huge safety and fire risk and needs to be addressed ASAP!!!! Upon my research, I’m finding several Hyundai Sonata vehicles having this same exact issue. Kia vehicles are being recalled for this same exact issue. Why isn’t the Hyundai Sonata??

NHTSA complaint #11758874 — an unverified report by a vehicle owner.

VISIBILITY/WIPER

Blower motor malfunction at night. Smelled something burning. Extremely hot and humid outside. Windows fogged up inside which greatly reduced visibility. Checked the multifuse which controls the ABS, oil pump, cooling fan, & Blower. I discovered a burnt connection on one of the terminals for the blower. This is a huge safety and fire risk and needs to be addressed ASAP!!!! Upon my research, I’m finding several Hyundai Sonata vehicles having this same exact issue. Kia vehicles are being recalled for this same exact issue. Why isn’t the Hyundai Sonata??

NHTSA complaint #11758874 — an unverified report by a vehicle owner.

BACK OVER PREVENTION: SENSING SYSTEM: CAMERA

The reverse camera only shows a black screen and will put drivers in danger while not being able to see behind them while reversing. This needs to be recalled and repaired. Especially in situations where a person is reversing out of a driveway onto a major/busy road. Sometimes it works, but a lot of the time it is just a black screen with the green, yellow, and red lines to indicate how far your wheel is turned. But it doesn’t allow you to actually SEE where you’re backing up into or the cars coming from either side of you while trying to back out. It’s very dangerous and it seems to a be manufacturer’s defect that needs to be addressed by the company itself, since they’re the ones who made and installed the product incorrectly.

NHTSA complaint #11758919 — an unverified report by a vehicle owner.

SEATS

The driver's power seat track master assembly (Part#88500-L0030) on my 2020 Hyundai Sonata suffered a catastrophic structural failure while operating. The black plastic bracket housing and aligning the electric drive motor fractured. This caused the motor to pull out of alignment, twisting the driver's seat violently sideways and permanently jamming the tracking rails. This is a chronic, repeat safety component failure on this specific VIN. The original factory seat track assembly suffered an identical mechanical failure and was replaced by warranty on 10/3/2023 at 46,369 miles. This second factory replacement unit failed in exactly the same manner on 8/13/2026 at 82,271 miles-lasting only 35,902 miles under normal operating conditions. I weigh 95 pounds. A driver's seat structurally shifting sideways dynamically presents an immediate, severe crash hazard. It instantly alters driver ergonomics, compromises the structural crash-anchoring performance of the seat frame, and potentially restricts pedal access to the brake and accelerator. The manufacturer is actively denying product liability by classifying internal structural breakages of shielded components beneath the cushion as user "damage" rather than an engineering or climate-related material defect. This tracking component must be formally investigated for systemic failure patterns to prevent accidents.

NHTSA complaint #11758369 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

The AC/heating blower motor circuit on my 2020 Hyundai Sonata failed intermittently due to extreme electrical resistance overheating and melting the terminal pins inside the engine fuse box. I took it to the dealership and they inspected it said it was out of warranty but it needed part number 18980-09910-FFF and wiring kit 91300L1000-FF to repair at a cost of 780.00 including parts, tax, and labor. This matches the severe design defect acknowledged in Hyundai TSB #25-EE-002H or alternative TSB-24-EEOO-1H. I filed case number 43138757 with Hyundai corporate. For now this just affects my air conditioning. However, the root failure is a known design defect that presents a severe vehicle fire hazard and potential loss of windshield defrosting capability, lights, etc. if the whole electrical system should fail. As you should know the engine bay fuse box (which currently has melted parts) is the "brain" for the car's electrical distribution. It doesn't just power my AC fan; it holds the fuses and relays for the cars fuel pump, engine control module (ECM), headlights, and electronic power steering. If left unfixed and over time as the plastic melts, copper wires will cross and touch each other, causing a massive short circuit. My engine could suddenly cut out and stall while I am traveling at 70 mph on the highway, instantly killing my power steering and power brakes and putting me in extreme danger. Again not to mention the fire hazard this situation is likely to cause. This should be addressed via a mandatory safety recall, so that I don’t have to pay for a known engineering design defect and in case the TBS bulletin fails or further unknown damage has already occurred.

NHTSA complaint #11757743 — an unverified report by a vehicle owner.

SEATS

Car was taken to dealership for inspection. Upon inspection, it was determined that the fuel tank had expanded and pushed towards the heat shield, and expanded upward pushing up the back seats of vehicle. It was determined to not safe to drive. Manufacturer contacted me and offered a buyback. Upon their offer of a buyback, it was determined that I would owe the manufacturer approximately $2,000. I have requested that they fix it, and they have refused to give me the paperwork I requested about the car's condition and fixability. I am in the process of negotiating and am filing this complaint for the record.

NHTSA complaint #11753819 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Car was taken to dealership for inspection. Upon inspection, it was determined that the fuel tank had expanded and pushed towards the heat shield, and expanded upward pushing up the back seats of vehicle. It was determined to not safe to drive. Manufacturer contacted me and offered a buyback. Upon their offer of a buyback, it was determined that I would owe the manufacturer approximately $2,000. I have requested that they fix it, and they have refused to give me the paperwork I requested about the car's condition and fixability. I am in the process of negotiating and am filing this complaint for the record.

NHTSA complaint #11753819 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Car was taken to dealership for inspection. Upon inspection, it was determined that the fuel tank had expanded and pushed towards the heat shield, and expanded upward pushing up the back seats of vehicle. It was determined to not safe to drive. Manufacturer contacted me and offered a buyback. Upon their offer of a buyback, it was determined that I would owe the manufacturer approximately $2,000. I have requested that they fix it, and they have refused to give me the paperwork I requested about the car's condition and fixability. I am in the process of negotiating and am filing this complaint for the record.

NHTSA complaint #11753819 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

Fan motor fuse box quit working and ac/heat no longer operational. First time was around October 21, 2025.

NHTSA complaint #11751988 — an unverified report by a vehicle owner.

POWER TRAIN

My vehicle while driving, it is jerking and shaking. When I come to a stop, the cars rpms go up and down while the car is shaking. When I pressed the gas pedal to accelerate the car will not accelerate as normal and the car jerks as I’m driving it. The RPMs rev up and down without any pressure placed on the gas pedal. The check engine light came on.The miles per hour only allows me to put one digit. I wanted to clarify that the problem is occurring anywhere between 0 mph to 65 mph when these the car jerks and shakes and the RPMs go up and down without me pressure on the gas pedal.

NHTSA complaint #11749650 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

My vehicle while driving, it is jerking and shaking. When I come to a stop, the cars rpms go up and down while the car is shaking. When I pressed the gas pedal to accelerate the car will not accelerate as normal and the car jerks as I’m driving it. The RPMs rev up and down without any pressure placed on the gas pedal. The check engine light came on.The miles per hour only allows me to put one digit. I wanted to clarify that the problem is occurring anywhere between 0 mph to 65 mph when these the car jerks and shakes and the RPMs go up and down without me pressure on the gas pedal.

NHTSA complaint #11749650 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the low oil warning light illuminated. The contact added oil to the engine. The dealer was made aware of the failure. The vehicle was taken to the dealer several times, and several oil consumption tests were performed. The contact was informed that the oil consumption test results did not indicate excessive oil consumption. The failure reoccurred. The vehicle was taken to the dealer, and the contact was informed that the oil level was a half quart low. The contact was informed that no repair options were available. The manufacturer was not made aware of the failure. The failure mileage was approximately 80,000.

NHTSA complaint #11749550 — an unverified report by a vehicle owner.

ENGINE

My vehicle while driving, it is jerking and shaking. When I come to a stop, the cars rpms go up and down while the car is shaking. When I pressed the gas pedal to accelerate the car will not accelerate as normal and the car jerks as I’m driving it. The RPMs rev up and down without any pressure placed on the gas pedal. The check engine light came on.The miles per hour only allows me to put one digit. I wanted to clarify that the problem is occurring anywhere between 0 mph to 65 mph when these the car jerks and shakes and the RPMs go up and down without me pressure on the gas pedal.

NHTSA complaint #11749650 — an unverified report by a vehicle owner.

SEAT BELTS

The seat belt latches do not latch or will spontaneously unlatch. This has been a problem for about 4 years. I have checked for recalls and not seen any for my car. I will check with the dealer but have tried vacuuming the latches without effect. I have never experienced anything like this in any previous vehicle. The warning buzzer lets me know when the seatbelt unlatches, but I seriously doubt the belt would hold in case of an accident.

NHTSA complaint #11749402 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

No air coming from cabin, upon further inspection found melted multifuse with melting terminal pin area in fuse box. No prior signs of warning, leaving vehicle without operable air condition for high temperatures.

NHTSA complaint #11746626 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed with the family inside the vehicle, a strong gasoline odor was inside the cabin of the vehicle. The contact stated that the fuel gauge was lowering quickly. Upon exiting the vehicle, the contact became aware of gasoline gushing heavily out of the vehicle onto the ground. Two months prior to the failure, the vehicle was taken to an authorized dealer due to an abnormal sound coming from the rear of the vehicle. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the recall repair was not performed because the part for the recall repair was not yet available. The vehicle was towed to a dealer where it was determined that the gas valve was not properly fixed. The abnormal sound in the rear of the vehicle was due to the fuel expansion, which caused the tank to rupture and melt. The melting caused the fuel pump to expand and melt, causing structural damage to the body of the vehicle. The structural expansion caused the rear passenger seats to raise up. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 89,000.

NHTSA complaint #11745596 — an unverified report by a vehicle owner.

STRUCTURE

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed with the family inside the vehicle, a strong gasoline odor was inside the cabin of the vehicle. The contact stated that the fuel gauge was lowering quickly. Upon exiting the vehicle, the contact became aware of gasoline gushing heavily out of the vehicle onto the ground. Two months prior to the failure, the vehicle was taken to an authorized dealer due to an abnormal sound coming from the rear of the vehicle. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the recall repair was not performed because the part for the recall repair was not yet available. The vehicle was towed to a dealer where it was determined that the gas valve was not properly fixed. The abnormal sound in the rear of the vehicle was due to the fuel expansion, which caused the tank to rupture and melt. The melting caused the fuel pump to expand and melt, causing structural damage to the body of the vehicle. The structural expansion caused the rear passenger seats to raise up. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 89,000.

NHTSA complaint #11745596 — an unverified report by a vehicle owner.