Recall 232 – Power Relay Under Rear Seat May Cause Fire – 2017-2018 Hyundai Ioniq HEV & Ionic PHV

June 28, 2022 NHTSA CAMPAIGN NUMBER: 22V459000

Power Relay Under Rear Seat May Cause Fire

An overheated PRA increases the risk of a fire.

 

NHTSA Campaign Number: 22V459

Manufacturer Hyundai Motor America

Components HYBRID PROPULSION SYSTEM

Potential Number of Units Affected 10,575

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2017-2018 Ioniq HEV and Ionic PHV vehicles previously recalled under recall number 18V-704. The Power Relay Assembly (PRA) located underneath the rear seat may overheat.

 

Remedy

Dealers will inspect and replace the main relay or PRA, as necessary, free of charge. Owner notification letters are expected to be mailed August 26, 2022. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 232. This recall replaces NHTSA recall number 18V-704. Vehicles already repaired under the previous recall will need to have the new remedy completed.

 

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

 


2018 Hyundai Ioniq
2018 Hyundai Ioniq

 


RECALL 232 ATTACHMENT A
CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

 

March – August 2018

On March 7, 2018, HMC received a report indicating heat damage on the rear seat of model year 2017 Kia Niro sold in the Korean market.  HMC immediately began testing to determine the cause of the damage under various driving conditions and maneuvers.  As of June 2018, HMC was unable to replicate the phenomenon.  HMC began focusing its investigation on component testing with the supplier.  This testing concluded in August 2018 and the phenomenon could not be replicated by component bench testing alone.

 

September 2018

HMC conducted additional testing and on September 18, 2018, HMC was able to replicate the phenomenon.  An inspection of the damaged rear seat revealed that the damage was caused by increased heat generated by the PRA.  Further inspection of the PRA revealed that the main relay was loosely connected, indicating that the heat was likely caused by increased electrical resistance as a result of loose contact between the main relay terminals.  In addition, HMC noted that the main relay originated from a previous supplier that used lower manufacturing specifications for terminal tightening torque and contact pressure.  Main relays provided by the current supplier were produced with higher specifications for terminal tightening torque and contact pressure.

 

October 2018

HMC notified all regional distributors of the affected vehicles and informed them of their findings.  After conducting its own search of related field information, HMA convened its Technical Committee on October 2, 2018, and decided to conduct a voluntary safety recall to address the condition in the subject vehicles.

 

June 2021

On June 26, 2021, HMA received a report of a 2017 Ioniq vehicle that allegedly caught fire after receiving the remedy specified for Recall 178.  HMA’s NASO began monitoring field information for post-remedy fires on all vehicles that were repaired under Recall 178.

 

November – December 2021

On November 29, 2021, HMA received a report of a 2017 Ioniq vehicle that allegedly caught fire after receiving the remedy specified for Recall 178.

On December 20, 2022, HMA was notified of an additional incident involving a previously remedied 2017 Ioniq vehicle that caught fire.  The November and December incident vehicles were available and requested for inspection and further analysis.

 

January – February 2022

NASO recovered two incident vehicles and a joint inspection was performed on February 24, 2022 with representatives from HMC, HMA, and Hyundai’s North American Quality Center (“NAQC”).

Hyundai found that both vehicles were still equipped with the original factory-installed relays despite both vehicle’s repair history displaying the remedy for Recall 178 was previously applied.  The prior remedy for each inspected vehicle was applied by separate dealers.

 

March – May 2022

In March 2022, Hyundai received notice of two (2) additional post-remedy fire cases at two additional dealers.

From March through April 2022, HMA coordinated a survey of vehicles repaired by the subject dealers under Recall 178 to identify additional vehicles that might have been impacted.  NASO identified four (4) vehicles that were improperly repaired, out of eleven (11) total vehicles surveyed, bringing the cumulative count of known incidents to nine (9).

 

April – May

The HMA Audit team conducted a routine warranty audit for one of the previously identified dealers to review all processes related to recall campaign repair, completion, and warranty filings related to Recall 178 and compliance with internal and federal requirements.

 

June 2022

On June 14, 2022, NASO met with several HMA departments to review the audit findings and discuss possible future activity related to recall and campaign compliance.

On June 17, 2022, HMA convened its North America Safety Decision Authority and decided to initiate a new safety recall of all vehicles previously involved in Recall 178 in the U.S. market.

As of the date of this filing, Hyundai has identified nine (9) total reports of the defect condition in the subject vehicle population received from June 26, 2021, through March 6, 2022.  There are no confirmed crashes or injuries related to the subject defect condition in the U.S.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
HYUNDAI IONIQ HYBRID 2017-2018
HYUNDAI IONIQ PLUG-IN HYBRID 2017-2018

 


3 Associated Documents

Recall Acknowledgement

RCAK-22V459-5648.pdf 644.989KB

RCAK-22V459-5648

 


ATTACHMENT A: CHRONOLOGY

RMISC-22V459-9707.pdf 125.667KB

RMISC-22V459-9707

 


Defect Notice 573 Report

RCLRPT-22V459-7197.PDF 214.064KB

RCLRPT-22V459-7197

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V459&docType=RCL

 


 

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