NHTSA Complaint #11601188 — 2013 HYUNDAI SANTA FE

Hyundai sent a notification a few years ago about a known manufacturing defect in the engine of the 2013 Santa Fe Sport. Stated that due to the manufacturing process of the engine, burs could be left inside that could disrupt oil flow causing it to stall. Stated a software patch would prevent this. The patch was completed. It didn't prevent this. While getting on the highway, during afternoon noon rush hour traffic, experienced total engine failure as soon as it reached highway speed. Got off the ramp onto the highway and immediately next ramp rolled to a stop at the bottom. Safety was put at risk because the vehicle lost it's engine getting on a freeway in heavy traffic. Hyundai dealers couldn't see the car for 2 to 3 months so had it towed to a non-dealership mechanic who stated the engine was a total loss with metal shavings in the oil drained from the pan. Pulled the head and found the oil at the top of the block to be in good maintenance shape but engine totally failed. No lights or warnings prior to the failure. As soon as the engine stopped there was alternator, oil pressure, and check engine light. Those came on after loss of engine Hyundai states they extended the warranty to cover this because it's a known issue but local dealerships state they have so many engine failures they won't be able to look at it until the end of September (we are at the beginning of July) and when they do get a chance to look at it there is a chance they could refuse to cover it. Contacted Hyundai customer support where they stated there's nothing they can do. Currently vehicle is being stored in my garage pending outcome of inspection that's months away.