Hyundai Oil Drain Plug Issues Prompt NHTSA Investigation

Learn more about how a Hyundai oil drain plug can loosen and fall out, causing oil leaks and engine damage

The NHTSA Office of Defects Investigation (ODI) has received a petition on July 13, 2022, requesting a defect investigation into an alleged defect of Hyundai oil drain plug issues that cause the drain plug to loosen and leak oil or fall out, resulting a complete loss of oil. The investigation involves the  following 83 models/model year Hyundai

2006-2019 Hyundai Sonata
2013-2018 Hyundai Santa Fe Sport
2010-2012 and 2019-2020 Hyundai Santa Fe
2010-2015 and 2018-2019 Hyundai Tucson
2011-2021 Kia Sportage
2005-2020 Kia Optima
2011-2020 Kia Sorento
2010-2013 Kia Forte
2010-2013 Kia Forte Coup
2007-2010 Kia Rondo vehicles equipped with the 1.6L T-GDI Gamma, 2.4L Theta II GDI, 2.4L In-Line GDI Theta II, Kappa, and 3.8L V-Shaped GDI Lambda-II engines.

All the above vehicles uses similar drain pan assemblies and appear to experience the same type of failures.

Description of the Hyundai Oil Drain Plug Issues

NHTSA is investigating allegations of oil leakage failures occurring at highway speeds, without malfunction, indicator lights, or the leakage associated with under-tightening an oil drain plug, or a plug or pan with damaged thread. The alleged defects are causing engines to seize and loss of motive power.

NHTSA has received a number of complaints alleging complete engine failure from a variety of models stated above along with other models. The ODI complaints cited in the petition can be reviewed at NHTSA.gov under the following ODI numbers: 11481745, 11433038, 11366918, 11431200, 11320689, 11245086, 11196311, 11114946, 11114946, 11097819.
119 Associated Products
Vehicles
MAKE MODEL YEAR

HYUNDAI SANTA FE 2010-2020
HYUNDAI SANTA FE SPORT 2013-2018
HYUNDAI SANTA FE XL 2019
HYUNDAI SONATA 2006-2019
HYUNDAI SONATA HYBRID 2011-2019
HYUNDAI SONATA PLUG-IN HYBRID 2016-2019
HYUNDAI TUCSON 2010-2015, 2018-2019
HYUNDAI TUCSON FUEL CELL 2015
KIA MOTOR SPORTAGE 2021
KIA FORTE 2010-2013
KIA FORTE KOUP 2010-2013
KIA OPTIMA 2005-2020
KIA OPTIMA HYBRID 2011-2020
KIA OPTIMA PHEV 2016-2020
KIA RONDO 2007-2010
KIA SORENTO 2011-2020
KIA SPORTAGE 2011-2021

In tests, NHTSA has secured the oil drain plug to the proper torque as specified by the Hyundai and Kia shop manuals. Even thought he drain plug were properly tightened, the plugs loosened or fell out before the next oil change.

NHTSA is investigating the root cause of the oil drain plug problem as a drain plug gasket that stays attached to the oil pan due to the painting process during manufacturing. Also, the investigation is looking into the possibility of sub-standard metal thickness and vibration that causes the plug to self loosen and leak oil.

For more information on the Hyundai oil drain plug problem, visit the NHTSA here

©, 2023 Rick Muscoplat