NHTSA complaint #11733955

Owner complaint summary

My 2021 Hyundai Santa Fe (VIN starting with 5NM) began experiencing a significant failure of the air conditioning system during its third year of ownership. The vehicle developed a persistent refrigerant leak that now requires annual recharges to remain functional. Multiple inspections suggest the failure is due to a porous evaporator core, a component defect that is increasingly reported by owners of this model year as they reach the 3-to-5-year mark. Despite being a documented manufacturing issue, there is currently no recall or warranty extension for this expensive and vital system. The failure of the AC system in a high-humidity environment like South Florida creates a severe safety hazard: Loss of Visibility: Without a functional AC compressor to dehumidify the cabin air, the interior of the windshield fogs over rapidly and completely during rain. This occurs even when the defroster is set to maximum, as the system cannot remove moisture from the air without refrigerant. Driver Impairment: In extreme Florida heat, the cabin temperatures reach levels that cause heat-related fatigue and stress, compromising the driver’s ability to remain alert and react safely to road conditions. On several occasions during heavy Florida rainstorms, the windshield fogged so severely that I had zero visibility of the road ahead. Because the AC system had leaked its refrigerant, the defroster was unable to clear the glass. I was forced to pull off the highway in dangerous conditions because I could not see other vehicles or lane markings. This defect prevents the vehicle’s primary visibility safety equipment (the defogger) from performing its required function.