Hyundai recalls over 135,000 Santa Fe SUVs over electrical short risk that could cause fire; check affected models and what owners must do

Hyundai has announced a major recall affecting more than 135,000 Santa Fe SUVs in the United States due to a potential electrical short caused by an improperly installed motor cover, which could cause a fire. On October 2, the South Korean manufacturer issued a recall for 135,386 Santa Fe vehicles manufactured between December 28, 2023, and July 7, 2025. The issue involves the B+ positive terminal cover on the starter motor assembly. If incorrectly installed, the cover could touch the cooling fan assembly, causing an electrical short that could potentially lead to a crash.

According to the National Highway Traffic Safety Administration (NHTSA) recall report, Hyundai estimates about 1 per cent of the affected vehicles may have improperly installed covers. As of the recall date, Hyundai had received one report from November 2024 confirming signs of a thermal event, although no accidents, injuries, or fatalities have been reported in the US due to this issue.

Why the recall exactly?

As per the recall report, the affected units "may have been assembled with a cover that was not fully seated" over a terminal on the starter motor, leading to an issue in which the terminal may contact the cooling fan assembly, and cause a short. The notice noted that "an electrical short can increase the risk of an electrical fire."

What Hyundai owners should do

Owners of the recalled Santa Fe models will receive a notification by mail with instructions to take their vehicle to a Hyundai dealership for inspection. If necessary, the terminal cover will be reinstalled at no cost to the owner. Hyundai will also reimburse any out-of-pocket expenses related to the reinstallation.