Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Hyundai Santa Fe owners, lightly cleaned up (personal details are redacted by NHTSA).
Purchased a 2005 Hyundai Santa Fe and found afterward that the fuel tank was leaking from inside the plastic shell surrounding it. Discovered at that time that this is a common problem in states that have corrosion (road salt) and it is difficult to spot because of the plastic shell. Found that Hyundai had not done a recall but extended the warranty, but only an additional 5 years or 50, 000 miles on the fuel tank. Contacted Hyundai because local dealer stated that they (the company) have repaired these after the vehicle has exceeded 150,000 miles at company cost but I went through the steps with their consumer affairs division and was turned down. Vehicle cannot be driven because of leaking fuel right next to hot exhaust pipe. This needs to be a recall.
Gas tank is corroded and leaking fuel due to road salt because I live in the northeast. I was notified that Hyundai has "extended the warranty" on model years 2001-2006 up to 150,000 miles. I do not believe this "extended warranty" should have a mileage restriction, and I also do not believe this should be an extension of the warranty but an all our recall by Hyundai. Cars are leaking gas! My car has no other rust on it and I keep my car clean and parked in my garage. My gas tank should not be rusted out on a car that is 10 years old. I also own a 1999 and another 2005 Hyundai (elantra & sonata) and neither have any gas tank corrosion. This is a design flaw and a dangerous situation.
Tl* the contact owns a 2005 Hyundai Santa Fe. While driving 35 MPH, the contact noticed a fuel odor inside the vehicle. The failure recurred on numerous occasions. The vehicle was taken to an independent mechanic who diagnosed that the evac canister needed to be replaced. The vehicle was repaired; however, the failure persisted. The manufacturer was notified of the failure. The failure mileage was 55,000. Updated 10/19/16 the consumer stated the fumes caused the driver and passenger to become nauseous and nearly passed out while driving.
Tl* the contact owns a 2005 Hyundai Santa Fe. The contact stated that while driving, a fuel odor emitted in the interior and exterior of the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel tank was rusted and leaking. As a result, the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure and the VIN was not included in NHTSA campaign number: 06V317000 (fuel system, gasoline). The failure mileage was 94,000.
I was driving coming up to a turn, took the left turn, and accelerated like a normally do, the car's rpms went up to about 5 thousand rpms. I heard a pop like noise and the rpms just started dropping and there was no restriction on the gas pedal (felt like I was pushing air). The vehicle then just rolled once it was at about 10 MPH rpms went under 1 thousand and the vehicle died. When I tried to restart it it was just crank and crank, doesn't even sound like it wants to turn over. Please help.
Tl* the contact owns a 2005 Hyundai Santa Fe. The contact stated that there was a strong fuel odor coming from the vehicle, as well as a fuel puddle under the vehicle. The vehicle was not diagnosed nor repaired. The VIN was not included in NHTSA campaign number: 06V317000 (fuel system, gasoline). The manufacturer was not made aware of the failure. The approximate failure mileage was 96,000.
Car all of a sudden stopped running like normal. Can't go above 20 mph without sounding like backfiring or dying
We bought this vehicle in June 2013. We had it almost a month when the steering locked up on me. The power steering pressure line blew out. We took it to the dealer that we bought it from and they fixed the line. Three days later the steering went again we got it to the dealership and they were going to charge us $300.00. I got upset but the most they would do for me was split the cost.then a few months later I started to smell gas. I didn't see any thing on the ground so I left it go. Then in November 2013 the air bag light came on and also the seat belt light would come on and go off and the bell would ding as if the seat belt wasn't buckled but it was.I just had it tested by a Hyundai dealer and the mechanic said that there was a defective sensor in the seat belt assembly that causes the airbag light to come on and the seat belt light and bell to go off. …
Started engine. Placed the automatic transmission selection into reverse. The engine immediately had an unintended acceleration to perhaps 2500 RPM. Operator immediately applied very heavy pressure on the brake pedal to stop any rear direction movement. Operator immediately moved the shift lever back to the park position, shut off the ignition and restarted the vehicle. After restarting, everything was back to normal. This had also occurred one other time in September, 2013 under the same circumstances. Operator initially assumed that perhaps his foot had moved to the right and was depressing both the accelerator and the brake at the same time, but when attempting to see if this could be done, operator could not replicate. It is assumed the throttle sensor locator May be faulty. Very disturbing when this happens and could easily result in property or personal damage..
Sudden unintended acceleration. While driving my vehicle, the car "lurches" forward and the engine "reves" up. I've had it to the mechanic numerous times and they can not seem to find a reason for this to be happening. It is a very scary situation. I have 2 small children and have become fearful when driving my car. This happens on the highway as well as regular street roads. I've seen many forums on line with the same complaints from other Hyundai owners. I really hope that someone looks into these complaints.
Fuel System complaints in other Santa Fe years
Frequently asked questions
How common are fuel system problems on the 2005 Hyundai Santa Fe?
NHTSA has 22 complaints about the fuel & propulsion system of the 2005 Hyundai Santa Fe, 10% of the model year's 216 complaints. The component named most often is delivery (2 mentions).
Is there a recall for 2005 Hyundai Santa Fe fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Hyundai Santa Fe, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2005 Hyundai Santa Fe fuel system problems start?
Half of the complaints with a recorded mileage happened before about 94,000 miles, and 16% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 0 fires and 2 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.