1% or about 1,350, of the 135,386 recalled 2024 and 2025 Hyundai Santa Fe vehicles are estimated to actually contain the fire defect Hyundai has announced a recall for.
This recall involves the engine starter, which is responsible for starting the combustion cycle in the engine.
In rare events occurring after a crash, the starter can come into contact with a coolant fan and cause a fire. This danger is what prompted Hyundai to initiate the recall.
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What Causes the Starter Motor Defect
Based on NHTSA documents, the problem with the engine starter is likely linked to a manufacturing defect.
The starter motor assembly might have been assembled without being fully covered, leaving a terminal exposed.
Hyundai’s concern is that this terminal can come into contact with the cooling fan assembly during certain accidents, because that contact can lead to a short and potentially an electrical fire.
Ultimately, it appears that the defect is caused by that manufacturing error that left the terminal uncovered.
Why an Improperly Seated Starter Cover Creates Danger
As mentioned, the primary concern with the starter not being properly covered is that it can come into contact with the cooling fan during certain types of vehicle accidents.
If it does, it can cause a short and that short can cause a fire. Vehicle accidents are dangerous enough without any added risk from vehicle fires, and those car fires can be incredibly dangerous if individuals are caught in the fire or the fire results in explosions of any kind.
Even if the actual risk of fire is low, Hyundai recognizes that the risk is high enough and started this recall in response.
How Hyundai Plans to Repair the Starter Cover Issue
- Disconnect Negative Battery Terminal
According to Hyundai’s technical service bulletin, the first step in the repair process is for technicians to disconnect the negative battery terminal to ensure safety while working on the vehicle. - Remove Under Cover of Engine Area to Access Engine Starter
After disconnecting the battery, the under cover of the engine area is removed. This provides access to the engine starter and related components. - Inspect and Adjust Starter Cover as Necessary
With access to the starter, technicians will disconnect the starter signal wire connector and visually inspect the starter to verify that the starter cover is properly seated. If the cover is loose or misaligned, it will be adjusted or repaired to ensure proper coverage. - Reinstall Under Cover and Complete Repair
Once the inspection and any necessary adjustments are completed, technicians will reattach the under cover and finalize the repair process. At this stage, the vehicle is fully reassembled and the service is complete.
Owners will receive notification letters by mail on or around December 1, 2025, which will include additional details about where to take their vehicle and the next steps in the recall process.
What Owners Should Watch for Before & After the Repair
Because the problem is internal to the vehicle and only manifests after an accident takes place, there aren’t any specific signs that consumers should watch out for.
As a general matter, consumers should be careful while operating their vehicle and follow the normal rules of the road to avoid getting into an accident.
If you do get into an accident with or inside of an impacted vehicle, moving quickly and ensuring everyone exits the vehicle could help avoid the risks of a potential fire.
The most important step for an owner to take is to pay attention to updates regarding this recall and to take the vehicle in for repairs as soon as instructed to do so.
This ensures that the problem can be solved before an accident takes place and potentially causes a vehicle fire.
When Filing a Lemon Law Claim Might Be a Stronger Option
In some cases, filing a lemon law claim can be a stronger option for you if your vehicle continues to cause issues even after it has been repaired.
Lemon laws exist in nearly every state and exist for consumer protection, helping consumers be compensated for purchasing persistently defective vehicles.
These laws apply when a car experiences repeated problems that remain unresolved despite multiple repair attempts under the manufacturer’s warranty.
The defects covered typically involve serious issues affecting the vehicle’s safety, value, or everyday use.
Once a pattern of unsuccessful repairs emerges, the owner may have the right to file a lemon law claim seeking a replacement vehicle, refund, or compensation from the manufacturer.
The process generally begins by carefully documenting every repair visit and communication with the dealership.
Service invoices, work orders, and warranty records serve as critical evidence showing that the manufacturer was given a fair chance to correct the issue.
The consumer must also keep track of how long the vehicle has been out of service, since excessive downtime can independently qualify a car as a lemon.
An experienced lemon law attorney can review this documentation to confirm whether the legal criteria are met and guide the owner through the next steps of filing a claim.
When a claim is filed, the manufacturer has the opportunity to resolve the matter directly with the consumer.
This often results in a negotiated settlement, such as a buyback or a new replacement vehicle. However, if the manufacturer refuses to cooperate, the case can proceed to arbitration or court.
In most states, successful claimants can recover their legal fees from the manufacturer, which allows consumers to pursue justice without out-of-pocket costs.
Get in Touch with Experts in Lemon Law!
If you decide to pursue a lemon law claim, you don’t have to do so alone! Our team of attorneys at the Lemon Law Experts has decades of collective experience assisting consumers seek justice through the lemon law.
We would love to help you take the first steps to getting back on the road. Contact us today by calling (877) 885-5366 or by filling out an online contact form on our website.
Citations
National Highway Traffic Safety Administration, Part 573 Safety Recall Report, U.S.
Department of Transportation. https://static.nhtsa.gov/odi/rcl/2025/RCLRPT-25V659-2787.pdf. Accessed October 14, 2025.
National Highway Traffic Safety Administration, Letter to Hyundai Motor America, U.S.
Department of Transportation. https://static.nhtsa.gov/odi/rcl/2025/RCAK-25V659-9756.pdf. Accessed October 14, 2025.
Hyundai, Technical Service Bulletin (Starter Battery Terminal Boot Inspection/Adjustment), Hyundai. https://www.autoevolution.com/pdf/news_attachements/hyundai-recalls-135386-santa-fe-vehicles-over-fire-risk-from-starter-motor-258909.pdf. Accessed October 14, 2025.
