Hyundai Initiates Major Recalls for IONIQ 5, IONIQ 9, and Kona Models Due to Fire and Steering Risks

Hyundai Motor America has announced significant safety recalls impacting three of its popular vehicle models, according to a recent filing with the National Highway Traffic Safety Administration (NHTSA). The recalls affect certain 2025-2026 Hyundai IONIQ 5, 2026 Hyundai IONIQ 9, and 2026 Hyundai Kona vehicles due to potential defects that could lead to electrical fires or loss of steering control. Owners of these vehicles are strongly advised to take immediate action, as recommended by the manufacturer and safety regulators.

The recall for the 2025-2026 Hyundai IONIQ 5 and 2026 Hyundai IONIQ 9 electric vehicles, encompassing a total of 27 potentially involved units, addresses an issue with the Battery System Assembly (BSA). Manufacturing records indicate that insufficiently tightened retention bolts for the high-voltage bus bars within the BSA may loosen over time. This loosening could result in electrical arcing inside the battery pack, increasing the risk of an electrical fire. Additionally, loose connections within the high-voltage battery pack could trigger a voltage sensor error, potentially causing the vehicle to enter a limited drivability mode. The root cause has been identified as potential rework processes for the BSAs that may have bypassed automated torque verification. As of the filing date, Hyundai has not reported any field incidents, crashes, injuries, fatalities, or fires related to this specific condition.

In parallel, Hyundai is also recalling 4,555 model year 2026 Hyundai Kona vehicles equipped with gasoline engines. This recall stems from a defect in the front steering knuckles, which may have been improperly cast and installed in a single production lot. If subjected to high load inputs during certain driving maneuvers, a crack could develop in the knuckle assembly. A fractured steering knuckle could ultimately lead to a loss of steering control and increase the risk of a crash. The issue is attributed to contamination of the mold cavity following routine maintenance. No field incidents, crashes, injuries, fatalities, or fires have been reported in connection with this defect to date.

For both recalls, Hyundai will notify owners by first-class mail. The remedy will be provided at no cost to owners, regardless of warranty status. For the IONIQ 5 and IONIQ 9, dealers will inspect the BSA bus bar and tighten the retention bolts as necessary. In the case of the Kona, dealers will inspect the front steering knuckle lot information and replace the knuckle if it is found to be affected. Hyundai also advises owners of the affected vehicles to “Do Not Drive” and to park their vehicles outside due to the potential fire risk associated with the IONIQ models.

Hyundai has implemented enhanced process controls to prevent the recall condition in future production. For the IONIQ models, these enhancements include improved rework procedures and more frequent and stringent inspection criteria, implemented in November 2025. The supplier for the Kona vehicles repaired the affected mold on October 16, 2025, and remedy components are sourced from unaffected production lots.

Owners of affected vehicles will be notified by mail, and the remedy will be offered starting April 6, 2026. Vehicle Identification Numbers (VINs) for these recalls can be searched on the NHTSA website beginning February 7, 2026. Hyundai will also provide reimbursement for out-of-pocket expenses incurred by owners who have already sought repairs for these specific recall conditions.

Article by Mel Anara, based upon information from Hyundai Motor America and NHTSA

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