Hyundai Nexo recall exposes unique risk with hydrogen vehicles

Myriad combustion-powered and electric vehicles have been recalled for posing a fire risk over the years, but not in the way the Hyundai Nexo hydrogen fuel cell electric vehicle (FCEV) has.

The US National Highway Traffic Safety Administration (NHTSA) has published a recall for 1545 examples of the 2019-24 Nexo as they may pose a fire risk due to the leaking of hydrogen gas.

The recall notice calls on owners to park their vehicles outside and away from structures due to the fire risk posed.

Hyundai is set to follow the US recall with one for all 28 Nexos in Australia.

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No incidents have been reported in the US, Canada or Australia, though the recall was triggered following reports of the issue occurring in some Korean-market Nexos.

The Nexo is equipped with what’s called a Thermally activated Pressure Relief Device (TPRD), a device that vents hydrogen gas to the atmosphere to prevent overpressurisation of hydrogen fuel tanks in the event of overheating in the area surrounding them.

This venting is done through a glass bulb-type release mechanism.

Per the recall notice, this mechanism may prematurely fracture due to ‘microcracks’ in the glass, resulting in the inadvertent discharge of hydrogen gas during normal vehicle operation.

When this happens “a loud wind-rushing noise can be heard accompanied by a white fog-like cloud near the rear of the vehicle”, while the fuel gauge will quickly lower and a malfunction light will illuminate in the instrument cluster.

The risk of this defect is hydrogen gas could build up in a confined space, which could pose danger should there be an ignition source.

As part of the recall, Hyundai is replacing the glass-type TPRD with a metal-type item.

Hyundai had already started fitting this metal-type TPRD on the Nexo’s production line from May 21, 2024.

Nexos aren’t sold through Hyundai Australia showrooms, with the company instead leasing 20 examples of the FCEV to the ACT Government. Five Nexos also subsequently joined the Queensland Police Service fleet.

Riding a unique platform, the Nexo boasts 666km of WLTP range, and a claimed refuelling time of between 3-5 minutes.

However, while EV chargers are commonplace, hydrogen refuelling stations are much rarer in Australia.

There are just 13 currently operating or under construction in Australia, and not all are readily accessible with many being on mine sites, bus depots or at company headquarters.

MORE: Everything Hyundai Nexo