Hyundai is recalling more than 54,000 Elantra Hybrid sedans in the United States after discovering a defect that could cause the vehicles’ hybrid power system to overheat. In the worst-case scenario, the issue could increase the risk of an engine bay fire.
The recall affects certain 2024 through 2026 Hyundai Elantra Hybrid models equipped with a faulty Hybrid Power Control Unit, or HPCU. According to documents filed with the National Highway Traffic Safety Administration, the problem centers around an internal electronic component that can overheat under high electrical loads.
Hyundai says the issue stems from a metal-oxide semiconductor field-effect transistor, commonly known as a MOSFET, located inside the HPCU. Under certain driving conditions, the existing software may not provide sufficient cooling for the component, potentially allowing temperatures to rise beyond safe operating limits.
The automaker says the defect can trigger several warning signs before more serious damage occurs. Drivers may experience reduced power output, warning lights on the dashboard, or situations where the vehicle refuses to restart after being turned off.
Overheating Could Lead To Power Loss
According to the recall filing, overheating inside the HPCU can cause localized thermal damage to the unit’s assembly and internal electronics. Hyundai says affected vehicles may automatically enter a reduced-power “limp mode” designed to protect the hybrid system from additional damage.
In more severe cases, however, excessive heat buildup could create conditions capable of damaging surrounding components inside the engine bay. Federal safety regulators note that the issue increases the risk of a vehicle fire.
The defect is most likely to occur during periods of sustained electrical load, such as long highway drives, heavy traffic conditions, or driving in high ambient temperatures. Hybrid systems rely heavily on power electronics to manage the interaction between the gasoline engine and electric motor, making thermal management critical for reliability and safety.
Fortunately, Hyundai says no major hardware replacement is required for the fix. Instead, dealerships will install updated software intended to improve cooling performance and better manage electrical loads inside the control unit.
Software Update Will Be Performed Free Of Charge
Hyundai dealers will update the Hybrid Power Control Unit software at no cost to owners. The revised programming improves thermal management for the MOSFET while also limiting maximum current delivery to reduce the chances of overheating.
The company says the updated software also enhances monitoring and diagnostic capabilities to detect abnormal operating conditions before temperatures become dangerous. Hyundai will begin notifying affected owners by mail starting July 13.
Owners who previously paid out of pocket for related repairs may also qualify for reimbursement under Hyundai’s recall policy. Drivers can check whether their vehicle is included in the campaign by entering their VIN through the NHTSA recall database or Hyundai’s owner portal. The recall covers a total of 54,337 vehicles in the United States.
Hybrid Systems Face Growing Scrutiny
As automakers continue expanding hybrid and electrified vehicle lineups, power electronics and thermal management systems have become increasingly important areas of concern for regulators and manufacturers alike. Modern hybrids rely on sophisticated control modules capable of handling large electrical loads while operating under demanding conditions.
This is not the first time Hyundai has issued a recall involving hybrid system electronics. The Elantra Hybrid previously faced a software-related recall in 2023 involving motor control systems, though the latest campaign focuses specifically on overheating risks inside the HPCU.
The issue also highlights challenges tied to increasingly complex electrified drivetrains. As hybrid systems become more powerful and compact, manufacturers are under pressure to ensure cooling systems and electronic safeguards remain robust enough to handle extreme real-world conditions.
For affected Elantra Hybrid owners, the solution itself appears relatively straightforward. Still, any recall involving potential fire risks is likely to draw attention as automakers continue balancing efficiency, performance, and reliability in the transition toward electrified vehicles.