April 19, 2024 NHTSA CAMPAIGN NUMBER: 24V283000
Improperly Tightened Differential Bolts
A loss of drive power or differential lock up can increase the risk of a crash.
NHTSA Campaign Number: 24V283000
Manufacturer Hyundai
Motor America
Components POWER TRAIN
Potential Number of Units Affected 2
Summary
Hyundai Motor America (Hyundai) is recalling certain 2024 IONIQ 6 vehicles. The differential gear bolts in the gear drive unit may not be tightened properly, which can result in a loss of drive power or cause the differential to lock up.
Remedy
Dealers will replace the gear drive unit, free of charge. Owner notification letters are expected to be mailed June 18, 2024. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 259.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check if your Hyundai has a Recall
Hyundai Recall Campaign 259
Attachment A: Requested Chronology of Events Leading Up to Decision
❖ March 2024
On March 5, 2024, HMC initiated a new global investigation based on receipt of two (2) claims involving Kia vehicles in certain foreign markets that exhibited noise while driving due to a faulty MGDU. HMC subsequently notified NASO of its initial assessment of both incidents.
On March 28, 2024, HMC informed NASO of information obtained from the Tier 1 supplier pertaining to a mis-shipment of MGDU assemblies intended for rework by the Tier 2 differential gear supplier. According to HMC, the bolts securing the differential gear to the housing were insufficiently tightened during assembly, leading to disengagement and a subsequent loss of motive power, as confirmed through testing of Kia vehicles retrofitted with defective MGDU units. HMC began tracking down vehicles potentially containing MGDU assemblies from the suspect lot and informed NASO that five (5) IONIQ 6 vehicles may have been delivered to the U.S. and Canada equipped with defective MGDU assemblies. NASO confirmed that two (2) AWD-specification vehicles were sold in the U.S. equipped with potentially affected rear MGDU assemblies.
❖ April 2024
On April 12, 2024, based on HMC’s investigation findings, HMA’s NASO convened its North America Safety Decision Authority (“NASDA”) and decided to conduct a safety recall of Hyundai IONIQ 6 vehicles potentially containing defective MGDU assemblies in the U.S. and Canada.
There are no incidents, crashes, injuries, or fatalities attributable to this condition in the U.S.
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| HYUNDAI | IONIQ 6 | 2024 |
3 Associated Documents
Defect Notice 573 Report
RCLRPT-24V283-3477.PDF 214.174KB
Recall Acknowledgement
RCAK-24V283-5134.pdf 645.324KB
Chronology Report
RMISC-24V283-3296.pdf 122.93KB
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-283
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Hyundai Motor America APR 19, 2024 NHTSA Recall No. : 24V-283 Manufacturer Recall No. : 259 Manufacturer Information :
Manufacturer Name : Hyundai Motor America Address : 10550 Talbert Avenue
Fountain Valley CA 92708
Company phone : 800-633-5151
Population :
Number of potentially involved : 2
Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2024-2024 Hyundai IONIQ 6 Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC
Descriptive Information : Based on manufacturing and sales records, the subject vehicles include certain model year 2024 Hyundai IONIQ 6 vehicles equipped with AWD and produced on the specified dates by Hyundai Motor Company (“HMC”) for sale in the U.S. market.
Production Dates : AUG 19, 2023 – AUG 21, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The subject vehicles are equipped with Motor-Gear Drive Unit (“MGDU”) differential gear assemblies containing differential gear bolts that may have been improperly torqued during assembly by the differential gear supplier. As such, the differential gear bolts can loosen over time and damage the MGDU housing and/or reduction gear during operation, which can cause a grinding noise potentially followed by differential lock-up or a sudden loss of motive power.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : A sudden, unexpected loss of motive power and/or differential lock-up could increase the risk of a crash, especially at high speeds.
Description of the Cause : A batch of MGDU assemblies requiring rework/tightening of the differential gear bolts was inadvertently delivered to the motor/reducer Tier 1 supplier by the MGDU Tier 2 supplier and used in production. Identification of Any Warning
that can Occur : Part 573 Safety Recall Report 24V-283 Page 2 Involved Components : Component Name 1 : MOTOR-GEAR DRIVE UNIT Component Description : Rear motor-gear drive unit assembly Component Part Number : 44000-18NB0 Supplier Identification : Component Manufacturer
Name : Hyundai Transys
Address : 105 Sindang 1-ro, Seongyeon-myeon Chungcheongnam-do Seosan-si Foreign States 31930
Country : Korea, Republic of Chronology :
Please see attached. Description of Remedy :
Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with
instructions to bring their vehicles to a Hyundai dealer to have the rear MGDU assembly replaced. This remedy will be offered at no cost to owners for all affected vehicles, regardless of whether the affected vehicles are still covered under Hyundai’s or Genesis’ New Vehicle Limited Warranty. Additionally, Hyundai/Genesis will provide owners of affected vehicles reimbursement for out-of-pocket expenses incurred to obtain a remedy for the recall condition in accordance with the reimbursement plan submitted to NHTSA on February 22, 2024.All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Hyundai dealer to have the rear MGDU assembly replaced.
This remedy will be offered at no cost to owners for all affected vehicles, regardless of whether the affected vehicles are still covered under Hyundai’s or Genesis’ New Vehicle Limited Warranty. Additionally, Hyundai/Genesis will provide owners of affected vehicles reimbursement for out-of-pocket expenses incurred to obtain a remedy for the recall condition in accordance with the reimbursement plan submitted to NHTSA on February 22, 2024. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-283
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
The differential gear bolts used in the remedy MGDU assemblies are properly tightened.
According to the supplier, several manufacturing process improvements were implemented from January to February 2024, including inspection of bolted areas using gap measurement tooling, revised rework schedules, designated rework areas, and implementation of a barcode for lot trace- ability scanning. Recall Schedule :
Description of Recall Schedule : Dealers will be notified electronically on the specified dates. Owners will
be notified via certified mail on the specified dates.
Planned Dealer Notification Date : JUN 18, 2024 – JUN 18, 2024
Planned Owner Notification Date : JUN 18, 2024 – JUN 18, 2024
* NR – Not Reported
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