2022 Hyundai Ioniq 5

Complaint Summary: Mandated federal safety recall remedies performed on my vehicle have directly induced a cascading, critical safety failure of the vehicle's high-voltage propulsion management system. My 2022 Hyundai IONIQ 5 (VIN: [XXX]) was brought to an authorized dealer on XXX at 200,224 miles to complete safety recall Campaign 272 / NHTSA Recall 24V-204 (ICCU Software Update and Fuse Inspection). After receiving this software flash, the vehicle's electrical charging system failed (DTC P0D5C00), requiring a full hardware replacement of the Integrated Charging Control Unit (ICCU) on XXX. 142 miles after the physical replacement of the high-voltage ICCU, the vehicle displayed an emergency battery malfunction message on the dashboard. Diagnostic scans reveal active fault code P1BC700 in the Battery Management System. The manufacturer's dealership is now charging $1,909.77 out-of-pocket to replace the Power Relay Assembly (PRA).The current recall modifications for the E-GMP platform are failing to safely mitigate high-voltage current spikes. The electrical strain or servicing procedure required by the recall has directly compromised the adjacent power relays. This creates a severe safety hazard, leaving drivers exposed to subsequent high-voltage component failure immediately after completing mandated federal safety recalls. NHTSA should investigate cascading high-voltage component failures occurring in vehicles directly following the completion of Recall 24V-204. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Experienced ICCU failure under everyday conditions, driving home from an appointment. Car had sat in direct sun for 30 mins, and starting the car and driving away with the AC fully blasting is when the failure occurred.

Component that failed: High-voltage main battery pack assembly and associated electrical architecture. The vehicle and the component are currently located at my home and are available for inspection upon request. Description of Incident & Safety Risk: While attempting to drive the car and when connected to the vehicle to a standard charging infrastructure, a catastrophic internal failure occurred within the high-voltage system (Diagnostic Trouble Code P1AA600). Upon attempting to plug the vehicle in, active electrical arcing and physical sparks emanated from the high-voltage architecture. This structural manufacturing component defect presents an immediate, severe, and active fire and safety hazard to the occupants, the vehicle, and any surrounding property. The vehicle is currently completely un-driveable and unsafe to connect to any power grid. Dealer Confirmation & Inspection: The vehicle was driven to a certified manufacturer dealership service center. A certified dealership technician formally inspected the vehicle, reproduced the fault, and explicitly documented the active electrical arcing and sparking coming from the high-voltage pack in the official service records. The vehicle history was also escalated to the manufacturer's executive consumer affairs team, who acknowledged the intake statement but refused to authorize a remedy or repair. Warning Symptoms: There were no long-term warning lamps or prior symptoms leading up to the structural breakdown. The high-voltage system failure occurred suddenly and catastrophically, immediately triggering a critical malfunction indicator on the dashboard cluster at the time of the failure.

The ICCU failed to charge the car via level 1 (120VAC or 240VAC), but does charge using public DC chargers. Fortunately the issue occurred at home so no traffic issue occurred, in this case. The level 1 charger indicated a fault and would not charge the car. I drove the vehicle without any issues to a public charger and established that the DC charging is working. Hyundai repair center diagnosed the problem and confirmed that a repair is needed. I am currently awaiting a repair. The fault was diagnosed on January 22, 2026 and as of June 01, 2026 no repair has been done.

Unknown. It just happened in November and i called Hyundai but they didn't want to fix it. I haven't been able to use my car properly since then.

ICCU failure. I received a message that said "Check electric vehicle system." Then seconds later another message that said "Stop vehicle and check power supply." Vehicle became nonfunctional (with my [XXX] daughter in the car) and had to have it towed to the nearest Hyundai dealership. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The battery is charged but will not start. It says pull over safely before it goes completely dead.i can jump the battery but it does not continue after being turned off. Slow and hard turning.

I tried to start car and it started but would not go into drive. A message saying "12v battery voltage low. Stop safely." Was on the screen. I turned the car off and back on and was able to drive home. Once home I tried to charge the car but it would not charge. However I left it plugged in and came back several hours later and the car had charged some. I started the car and the messages did not appear. The next day i went to drive the car and the car was totally dead. The auto key would not unlock the car. Thank goodness , I was not driving when the battery died. I took it to the dealer. This is the 2nd 12v battery I have had to replace in 4 years. The first replacement was covered under warranty. I asked them to try to identify the root cause of the 12v batteries dying so quickly and they claim it is only the 12v battery. I feel unsafe driving the car now knowing it could happen at any moment again, maybe while driving. I think the problem is related to the ICCU as my symptoms are very similar to other people with ICCU issues.

While the vehicle was parked in a garage and charging overnight, I briefly went to the vehicle to retrieve an item from the back seat. I was barefoot at the time. I opened the driver‑side rear door and reached inside with my right hand while my left hand was near the upper door area where the door seal is located. When my left hand grazed the door frame, it felt unusually sharp. When I touched the area again to determine what was sharp, I received a significant electric shock. There were no warning lights, messages, or prior symptoms before the incident. The presence of electrical current on an exterior door surface poses a safety risk during normal vehicle use.

2022 Ioniq 5 SE. ICCU failed April 2026 with around 29325 miles. Original owner. Purchased June 2022. I had the original Recall 272 software update performed back in February 2025, but the hardware still failed a year later. **Timeline of Failure:** 1. **Phase 1 (The Trigger):** Level 2 charging stopped unexpectedly before reaching the limit. It tripped my house breaker and unfortunately killed my Level 2 EVSE (Grizzl-E) with a stuck relay. Didn't think too much of it because I had to be somewhere. Car started up normally and I was able to drive throughout the day with no problems. 2. **Phase 2 (The Warning):** The next day, I attempted Level 1 charging. It immediately tripped the breaker. I tried another outlet on a different breaker; the breaker didn't trip, but the car failed to initiate a charge after three attempts. 3. **Phase 3 (Dashboard Error):** After third failed attempt with the L1, I took a peek inside and saw the dashboard had a yellow triangle. With the charger still plugged in, I sat in the driver's seat and turned the car on. The **"Check EV System"** error appeared. I turned off the car and went inside to call the dealer. I called the dealer and they said I can have it towed there. They also scheduled an appointment for the next morning. I went back to car to attempt to position the car to make it easier for the tow truck, but the check ev error was not there when I turned on the car. It said ready and I was able to drive around the block a few times so I figured I'll just try to drive to the dealer. I drove the car to the dealer the next morning. It took **one week** to get my car back. **Diagnostics & Parts Replaced:** The dealer confirmed the following codes and performed a full hardware replacement: * **DTC P1E1300:** AC Power Module Failure * **DTC P1A9096:** DC/DC Converter Fault * **ICCU Part:** `36400-1XAA0-AQQH` * **HV Fuse:** `375F2-GI040-QQH` * **Coolant:** Install of Pink Antifreeze (`00232-19098`)

The ICCU unit went out rendering the car inoperable

The car lost power while driving and an electrical warning was displayed on the screen. The issue was later diagnosed as a failure of the ICCU and blown fuse that had been previously recalled and replaced. Now it needs to be replaced again.

Finished charge, low battery indicator on the dashboard. started to drive, within mile "pull over immediatedly" well documented and continued flaw with vechile ICCU component (that I had the software "patches" applied). Car will no longer accept charge (so now has the remaining charge before being a 3 ton brick) and cannot not be driven as if the 12v battery loses charge (which it will) I will lose powersteering and brakes.

The 2022 ioniq 5 was bought used with 43k MI and within 2k miles of driving in 50-85F climate and 7kwh l2 charging I witnessed the orange check EV light flash while I was driving on the highway. I exited and powrr cycled the car and the EV light remained. The next morning the orange check EV light was gone. I went to the dealership for a diagnostic and they said they could not replicate the error code or had found any history of the error code coming up without proving to me or showing me any substantial evidence that they tested for anything at the Escondido Hyundai dealership in California. I escalated the issue with Hyundai corporate and was assigned a case manager that ultimately gave me the same answer that they could not replicate any codes and that I should take the car back and drive normally. After extensive research I found that the orange check ev light is a more dangerous sign than the red check ev light because it indicates that the ICCU unit is about to fail. Research shows that due to thermal stress the ICCU will inevitably fail after the orange check AV light comes on. Further research shows that Hyundai had officially stated a 1% failure rate for the ICCU unit in all of their EVs built on the e-gmp cars to date but some projections are at 10% failure rate or higher and that Hyundai Kia is downplaying the issue similarly to how they tried to do the same with the Theta 2 GDI engines that they had been sued and were responsible to pay over $300 or so million dollars as well as $24 million to a employee whistleblower a few years ago. I highly suggest that the nhtsa or other organizations that have the power to force Hyundai Kia to do the right thing so that no further lives are at risk from these ICCU units that have flawed designs that have not been fixed,only remedied via software update or replaced with refurbished units at the most with inevitable failure as thermal stress is experienced.

In summer 2025, the ICCU (Integrated Charging Control Unit) failed and was replaced under a Hyundai recall at no cost. On December 4, 2025, warning lights reappeared. College Park Hyundai diagnosed a faulty battery related to the prior ICCU failure. I paid out of pocket for a 12-volt battery replacement and additional maintenance, as the dealership claimed the battery was not covered. A “Check Electric Vehicle System” warning appeared immediately after I picked up the vehicle that same day. On December 5, 2025, I returned the vehicle to College Park Hyundai with 20,415 miles. They diagnosed a failed main EV drivetrain battery requiring warranty replacement. As of April 5, 2026, my vehicle has been at the dealership for 122 consecutive days with no repair completed, no replacement battery received, and no estimated completion date. Despite repeated follow-ups, I have received no meaningful updates on repair status or battery availability. I have been without my vehicle for four months with no resolution in sight. This extended delay represents a significant safety concern and an unacceptable failure of Hyundai’s warranty obligations.

Factory installed Michelin Primacy AS tires with acoustic foam lining. All 4 tires had acoustic foam coming loose and wadding up inside the tire, resulting in extreme vibrations (similar to a severely unbalanced tire) approaching and at highway speeds making vehicle difficult to control. Initially had the tires re-balanced in an attempt to fix before the problem was fully understood, but that solution did not last. Ultimately had the tires dismounted and foam pulled out, then rebalanced.

Upon starting the car, it made an audible "pop", and the dash indicated to check the 12V power supply and "low available power" with a turtle indicator, and an "EV!" warning lamp. The car struggled to accelerate out of the parking lot, and within a minute, the dash displayed a "power failure" message, and the car lost all ability to accelerate while on the road, forcing an emergency pull-over. The 12V system completely failed while waiting for a tow truck, complicating the already poorly-documented and complicated process of disengaging the vehicle's automatic parking break for loading onto the flatbed trailer. The dealership performed diagnostics and confirmed an ICCU failure. After waiting for parts and technician availability, the ICCU was replaced with part number 36400-1XAA0-AQQH "ICCU Assy" and returned to me 32 days later.

I am filing this complaint regarding Hyundai Motor America's failure to complete a vehicle repair in a timely manner on my 2022 Hyundai Ioniq 5 (VIN: [XXX] ), which has been at Hyundai of Leander, an authorized Hyundai service center in Leander, Texas, since September 2025 — more than six months — awaiting a replacement high-voltage battery. (Case No. XXX) I purchased this vehicle in September 2025 from Apple Sport Imports in [XXX] . The vehicle was sent immediately to Hyundai of Leander for an open repair and I never took full delivery. I was informed the replacement battery was initially allocated to a different dealership and a new order could not be placed until approximately January 2026. As of March 2026, Hyundai's own case manager confirmed in writing on March 30, 2026 only that they are working to determine the battery's arrival date with no confirmed completion date provided. Since November 2025, I have made 5 monthly payments of $513.92 totaling $2,569.60 on a vehicle I have never driven, with a sixth payment of $513.92 due in April 2026. I am also flagging a potential records discrepancy for NHTSA's awareness. When I checked my VIN on Hyundai's recall lookup website, Recall 272 — covering an ICCU software update, fuse replacement, and ICCU replacement on 2022-2024 MY IONIQ 5 vehicles — is listed as a Closed Campaign with a completion date of October 24, 2025. My vehicle was physically at Hyundai of Leander awaiting parts on that date and remains there today. I do not know whether this recall is related to the current open repair, but I am flagging the potential discrepancy for investigation. When I raised this with Hyundai of Leander's service department, I received no clear explanation. I am requesting that NHTSA investigate Hyundai Motor America's recall fulfillment practices and the accuracy of their recall completion records for this vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

On January 19, 2026, the vehicle lost power while driving and required a tow to the local dealership. After inspection, the dealership determined that the ICCU was at fault and needed to be replaced. The ICCU part was backordered. The vehicle was inoperable for 6 weeks as we waited for the part to be available and installed.

ICCU failure occurred while vehicle was operating at 30 MPH, after being charged the night prior and unplugged in the morning at 100% capacity. A sudden pop was heard, and the vehicle indicated that an electrical fault would require the vehicle to be shut down as soon as safely possible. The vehicle went into limp mode and would not exceed 25 MPH.