This bulletin describes the procedure to replace the fuel tank bands on certain 2005-2007 MY Tucson (JM) vehicles. The fuel tank bands may become corroded over time and cause the fuel tank to become loose.
full bulletin at NHTSA ↗2005 Hyundai Tucson fuel system problems
moderate Owners of the 2005 Hyundai Tucson have filed 7 NHTSA complaints about the fuel system at roughly $1,200 to repair (U.S. federal records, as of August 2026). Source: NHTSA Office of Defects Investigation. See fuel system across all vehicles →
Complaints
7
Recalls
0
Avg fix
$1,200
| Model year | fuel system complaints |
|---|---|
| 2005 Tucson (this page) | 7 |
| 2006 Tucson | 4 |
When does it fail?
Of the 7 fuel system complaints filed for the 2005 Hyundai Tucson, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 4 model years of Hyundai Tucson we track for fuel system problems, this one carries the most owner complaints on file — 7.
No new NHTSA fuel system complaint has been filed on this vehicle in over 18 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting 4 most recent
2005 Hyundai tucson bad gas mileage. Consumer states that the vehicle does not get the gas mileage indicated. In the city it gets less. *kb
Tl*the contact owns a 2005 Hyundai tucson. While driving approximately 55-60 MPH, the vehicle intermittently hesitated and shut off. The vehicle is able to be restarted after 10 to 15 minutes. The vehicle has been to the dealer seven times regarding this failure, but they could not provide a remedy. The current mileage was 43,550 and failure mileage was 23,000. Updated 03-04-08 *bf updated…
The back hatch window of my 2005 tuscon broke, sending the right 1/2 of the window flying down about 2 feet. The back door/hatch latch is also broken, you can't shut it without pulling he latch back out manually first after opening it. Has been over a month and 1/2 ;parts still not all in. Also,the gas cap latch is rested and I fear next to break. *tr
2005 Hyundai tucson consumer feels that he was sold a lemon. He feels that he is not getting the proper miles to the gallon of gasoline while driving in the city.*mr the vehicle only gets 11 MPG in the city. *nm *jb
Had fuel system trouble with your 2005 Hyundai Tucson?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2005 Hyundai Tucson?
It's a documented issue but not catastrophic. 7 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Based on the 7 complaints filed, fuel system issues most often appear around 81,536 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Hyundai/Tucson.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.