Hyundai Nexo Problems — All Years, Common Issues & Reliability

I am submitting this complaint to report serious safety, usability, and infrastructure-related issues concerning my Hyundai NEXO hydrogen fuel cell vehicle. The vehicle has become unsafe and practically unusable due to multiple technical problems, lack of service support, and the widespread unavailability of hydrogen fueling infrastructure in the Bay Area of California. These issues collectively present safety concerns not only for me as the driver but potentially for other Hyundai NEXO owners who may be experiencing similar problems. I purchased the Hyundai NEXO with the expectation that it would provide reliable transportation supported by Hyundai’s service network and the hydrogen fueling infrastructure promoted alongside the vehicle. As a consumer, I was attracted to the NEXO because of its innovative fuel cell technology, environmental benefits, and Hyundai’s commitment to zero-emission vehicles. However, my ownership experience has been extremely difficult and concerning due to both vehicle performance defects and the lack of support required to maintain and operate the vehicle safely. One of the most concerning issues with the vehicle is that the regenerative braking system does not appear to function properly. Regenerative braking is an important component of the NEXO’s efficiency and safety systems. When it does not operate correctly, the vehicle does not slow down in the expected way, and the energy recovery system that is supposed to recharge the vehicle’s systems during deceleration does not function as intended. This raises concerns about both vehicle performance and braking predictability. Another significant issue is that the vehicle’s speed appears to be limited and does not go beyond approximately 60 miles per hour. This limitation occurs even under normal driving conditions where higher speeds are required, such as highway travel. Being unable to exceed approximately 60 mph presents a safety

The vehicle has a material operability limitation related to its fuel/propulsion system that was not disclosed at the time of sale. After purchase, the vehicle’s real-world operation is materially restricted due to fuel availability and system limitations that prevent reliable use as represented. The limitation affects the ability to operate the vehicle predictably and as intended. This issue is not cosmetic or preference-based. It affects normal vehicle operation and reliability. The condition is ongoing and reproducible. The dealer and manufacturer have been contacted. The condition has not been corrected.

Vehicle: 2023 Hyundai Nexo Limited VIN: [XXX] Mileage at failure: ~12,077 Location: California What is the problem? After Hyundai performed Safety Recall 269 (thermally-activated pressure relief device) on my vehicle, the vehicle developed a hydrogen leak and was declared unsafe. Hyundai advised that no repair remedy is available. When did this happen? January 13, 2026, during attempted pickup from the dealership following recall service. What happened? My vehicle was taken to an authorized Hyundai dealer for Safety Recall 269. On the evening of January 12, 2026, the service advisor called and said the vehicle was ready for pickup. When I arrived the next day, the dealer attempted to bring the vehicle out. A malfunction appeared, and after over an hour, I was told the vehicle was leaking hydrogen and was unsafe to release. The dealer retained the vehicle and provided a loaner. The following day I was informed that the vehicle would be bought back and that no repair remedy or parts are available. Why is this a safety issue? The vehicle is fueled by high-pressure hydrogen. A hydrogen leak presents an immediate risk of fire or explosion. This defect appeared only after recall service and renders the vehicle unsafe for operation or storage. What has the manufacturer done? Hyundai has not repaired the vehicle and has stated no remedy exists. Instead, Hyundai offered only to pay off the loan and provide a small cash payment, without repairing the safety defect. Has this happened before? No. The vehicle was operating normally before the recall service. What do you want NHTSA to do? I am requesting that NHTSA investigate Hyundai’s recall remedy for Safety Recall 269 on the Hyundai Nexo and determine whether the recall repair is causing or failing to prevent hydrogen leaks, and whether Hyundai is providing an adequate safety remedy. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The vehicle uses hydrogen fuel which is stored in three high pressure cylinders. Any fires or damage to the vehicle that affects the fuel system can result in an explosion. During a recent recall, customers were recommended not to park near structures because the car can explode and cause property damage. This is applicable to all hydrogen fuel cell vehicles available in the US.

Thermally Activated Pressure Relief Device (TPRD) - Fire Concern

A THERMALLY-ACTIVATED PRESSURE RELIEF DEVICE (TPRD) THAT VENTS HYDROGEN GAS TO THE ATMOSPHERE TO PREVENT OVER-PRESSURIZATION OF THE HYDROGEN FUEL TANK IN THE EVENT OF OVERHEATING IN THE LOCAL AREA AROUND THE HYDROGEN FUEL TANKS. THE TPRD IS DESIGNED TO VENTTHROUGH A GLASS BULB-TYPE RELEASE MECHANISM THAT FRACTURES WHEN A SPECIFICOPERTAING TEMPERATURE IS REACHED. THE GLASS BULB-TYPE MECHANISM IN THE SUBJECT VEHICLES COULD PREMATURELY FRACTURE DUE TO MICROCRACKS IN THE GLASS, WHICH COULD LEAD TO INADVERTENT DISCHARGE OF HYDROGEN GAS DURING NORMAL VEHICLE OPERATION. HYDROGEN GAS LEAKING IN CONFINED AREAS WITH THE PRESENCE OF AN IGNITION SURCE MAY INCREASE THE RISK OF A VEHICLE FIRE WHIEL PARKED. THE DEALER WILL NOT BE ABLE TO REPAIR UNTIL MAY 12, 2025

I WAS DRIVEN ABOUT 65 MILES WHEN SUDDENLY SHOW ON THE CLUSTER EMERGENCY BRAKE APPLY IT HAPPEN TODAY AND ABOUT 2 WEEKS BEFORE . I HAPPEN LIKE 5 SECONDS AND DISAPPEAR AND BOTH CASES.