Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| STRUCTURE - BODY | |||||
| 01360091 | 07/01/2001 | 621626 | Subject regarding shop manual correction for idle speed actuator resistance check. *yh | 09/27/2001 | |
| 9960001 | 12/01/1999 | 610122 | This tsb is being issued to provide body dimension information. *tt | 04/17/2000 | |
| 9950005 | 04/01/1999 | 604994 | Experiencing thumping / knocking noise from left front during right turn. *tt | 05/21/1999 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| STRUCTURE | ||||||
| EA08016 | HYUNDAI MOTOR COMPANY | 08/21/2008 | 04/20/2009 | FRONT SUB-FRAME CORROSION | 09V124000 | |
| In a letter dated april 14, 2009, hyundai-kia america technical center, inc (hyundai) notified nhtsa that hyundaiis conducting a safety recall of model year (my) 1999 through 2004 hyundai sonata vehicles manufactured prior to november 20, 2003 that are registered and operated in the following salt belt states and the district of columbia: connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, and wisconsin.hyundai is recalling the vehicles to remedy a condition where internal corrosion of the front subframe may lead to separation of the lower control arm at the forward mounting point and/or separation of the axle from the transaxle.this could result in a loss of vehicle control and/or vehicle disablement. the subframes will be inspected in the recalled vehicles using a procedure developed by hyundai to measure metal thickness.parts with perforations from corrosion or with metal below the specified thickness will be replaced with redesigned subframes.if the minimum metal thickness is met, drainage holes and rust proofing material will be added to the existing subframe. odi's analysis of complaint data revealed that 98% of the consumer complaints were from vehicles either originally sold or operated in saltbelt states. similarly 99.7% of the warranty claims were from vehicles originally sold or operated in saltbelt states.odi identified 105 reports of lower control arm detachment and/or axle separation from the transaxle through analysis of warranty and complaint information and consumer interviews.one hundred three (103) of the 105 incidents involved vehicles in states covered by the recall.in addition to the subject vehicles, hyundai also noted in the april 14, 2009 letter that my 2001 through 2004 xg300 and xg350 were also being recalled as they were manufactured with subframes similar in design the subject vehicles.based on hyundai's decision to conduct a safety recall this engineering analysis is closed. | ||||||
| STRUCTURE - FRAME AND MEMBERS | ||||||
| PE08029 | HYUNDAI MOTOR COMPANY | 04/22/2008 | 08/21/2008 | FRONT SUB-FRAME CORROSION | ||
| The office of defects investigation (odi) opened preliminary evaluation, pe08-029, on april 22, 2008, based on 40 consumer complaints alleging front sub-frame corrosion in model year (my) 1999 through 2002 hyundai sonata vehicles.complaints describe severe corrosion of the vehicle sub-frame in the area where the right-front lower control arm is attached.in some vehicles, sub-frame corrosion has caused complete or partial detachment of the control arm, resulting in wheel collapse or separation. in response to odi's information request letter for pe08-029, hyundai provided owner complaints, field reports, and warranty claim data for approximately 197,906 my 1999 through 2002 subject vehicles sold or leased in the united states.the base warranty for the subject vehicles is 60 months or 60,000 miles, whichever occurs first.according to hyundai, prolonged exposure to the road salts may result in corrosive damage to the subframe.hyundai redesigned the sub-frame early in the my 2004 production (november 2003) to address problems with premature corrosion of the crossmember near the right-front suspension attachment. odi's analysis of both complaint and warranty data for the my 1999 through 2002 sonata vehicles shows that the failure rates are significantly higher in salt belt states, which account for approximately 50 percent of vehicle sales and over 90 percent ofcomplaints and warranty claims related to the alleged defect (note:for purposes of this investigation the salt belt includes connecticut, delaware, the district of columbia, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia and wisconsin).according to hyundai, the alleged defect results in a progressive loss of structural integrity of the subframe and there is ample opportunity for the problem to be detected (by inspection, steering feel or tire wear anomalies) and repaired before it reaches a state where a safety related incident may occur.hyundai identified 4 allegations of vehicle disablement and 1 allegation of a crash; where the lower control arm broke from the vehicle while driving at 55 mph and the driver lost control and drove into a yard.there were no reported injuries.odi received a separate allegation of a crash, where the complainant alleged that while driving around a slight curve at 65 mph on a freeway, the vehicle sub-frame fractured and the driver lost control of the vehicle and went off the road.again, no injuries were reported.approximately one-third of the complaints to odi allege that the sub-frame corrosion resulted in a loss of control and/or a vehicle disablement due to wheel collapse or separation.this investigation has been upgraded to an engineering analysis (ea08-016) covering my 1999 through early-2004 hyundai sonata vehicles in salt-belt states and equipped with the subject sub-frame design to further assess the frequency and safety consequences of the alleged defect. | ||||||
| EA08016 | HYUNDAI MOTOR COMPANY | 08/21/2008 | 04/20/2009 | FRONT SUB-FRAME CORROSION | 09V124000 | |
| In a letter dated april 14, 2009, hyundai-kia america technical center, inc (hyundai) notified nhtsa that hyundaiis conducting a safety recall of model year (my) 1999 through 2004 hyundai sonata vehicles manufactured prior to november 20, 2003 that are registered and operated in the following salt belt states and the district of columbia: connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, and wisconsin.hyundai is recalling the vehicles to remedy a condition where internal corrosion of the front subframe may lead to separation of the lower control arm at the forward mounting point and/or separation of the axle from the transaxle.this could result in a loss of vehicle control and/or vehicle disablement. the subframes will be inspected in the recalled vehicles using a procedure developed by hyundai to measure metal thickness.parts with perforations from corrosion or with metal below the specified thickness will be replaced with redesigned subframes.if the minimum metal thickness is met, drainage holes and rust proofing material will be added to the existing subframe. odi's analysis of complaint data revealed that 98% of the consumer complaints were from vehicles either originally sold or operated in saltbelt states. similarly 99.7% of the warranty claims were from vehicles originally sold or operated in saltbelt states.odi identified 105 reports of lower control arm detachment and/or axle separation from the transaxle through analysis of warranty and complaint information and consumer interviews.one hundred three (103) of the 105 incidents involved vehicles in states covered by the recall.in addition to the subject vehicles, hyundai also noted in the april 14, 2009 letter that my 2001 through 2004 xg300 and xg350 were also being recalled as they were manufactured with subframes similar in design the subject vehicles.based on hyundai's decision to conduct a safety recall this engineering analysis is closed. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| STRUCTURE | |||
| 10/09/2008 | 130000 | 1 | 06/01/2002 |
| Tl*the contact owns a 1999 hyundai sonata. while driving approximately 35 mph on normal road conditions, the vehicle pulled to the right on its own. the contact maneuvered the steering wheel in the opposite direction of the vehicle. there were no prior warnings to this failure. the vehicle was still able to be driven and was taken to the authorized dealer for inspection. they stated that the failure was related to the front subframe near the front passenger side wheel. the vehicle is currently being repaired. the contact was concerned of the safety risk involved. the failure and current mileages were 130,000. updated 11/24/08 *cn updated 11/26/08. *jb | |||
| 04/17/2008 | 158000 | 1 | |
| I have a 1999 hyundai sonata, and i started to experience a wheel-bearing problem on the passenger side. when i took the car to my mechanic for a wheel bearing i was told that the engine cradle had rusted completely that it collapsed the lower passenger side a frame. the car is not safe to drive and the dealer want $ 1700 to replace the engine cradle. this is purely unacceptable for 1999 car literally falls apart. the consumers of this brand were shortchanged. a car structural integrity should last longer than 8 years. we need your help to get hyundai motorcars to issue a recall before serious injuries occur and to compensate those hard working folks that have lost use of their cars. *tr | |||
| 08/01/2006 | 1 | 05/01/1999 | |
| The bars, in the consumer's 1999 hyundai sonata, that hold the motor up were rusted through on one side and cracked and rusted on the other side . *ts the vehicle would not pass inspection because of the rust problem. *nm | |||
| 07/28/2000 | 1 | 06/25/1999 | |
| Consumer was traveling about35mph on a street and another vehicle came to a suddenly stop. when consumer looked up he had hit other vehicle from behind. upon impact, dual airbags didn't deploy, consumer states that airbag light came on 3 times prior to accident and now twice after. consumer hears rattle from trunk. sunroof lining loose. gas pedal vibrates while driving. when riding over bumps, there is a rattle in the right rear of the vehicle. *ak *slc | |||
| STRUCTURE - BODY - DOOR | |||
| 09/16/1999 | 03/01/1999 | ||
| May 27, 1999: car was taken in due to low fuel light remaining on at all times. sending unit was ordered. july 8, 1999: sending unit was replaced with new unit. low fuel light continued to remain on at all times. service department ordered another part (unsure of what this part was). july 22, 1999: returned car to service dept due to low fuel light remaining on at all times. description of service on this date: board-prin, gauge assy. after this service, light no longer remains on at all times, but during the next few months, we notice the low fuel light does not come on at all, even when gas gauge falls below empty. sept 16, 1999: (new complaint) reported that both front door speakers crackle and pop when radio is on and front doors are open. service dept checks wiring, but problem continues upon picking up the car. we also report that power door locks will lock on their own. this problem is not fixed. service dept says they cannot duplicate problem. december 7, 1999: we report once again that speaker wires pop and crackle mainly on passenger side door while radio is on. service dept reports they test drove car, but could not duplicate problem. we also once again report that power door locks will lock on their own while driving. service dept test drove car, but could not duplicate problem. july 3, 2000: report continued problem with front door speakers, power door locks, and low fuel light. parts ordered. sept 12, 2000: sending unit replaced again, however light still does not come on when gas gauge falls below empty. service dept repaired short to ground wires to fix popping in front door speakers. upon return home, problem continues. problem with power door locks also continues. | |||
| STRUCTURE - BODY - TRUNK LID | |||
| 07/28/2000 | 1 | 06/25/1999 | |
| Consumer was traveling about35mph on a street and another vehicle came to a suddenly stop. when consumer looked up he had hit other vehicle from behind. upon impact, dual airbags didn't deploy, consumer states that airbag light came on 3 times prior to accident and now twice after. consumer hears rattle from trunk. sunroof lining loose. gas pedal vibrates while driving. when riding over bumps, there is a rattle in the right rear of the vehicle. *ak *slc | |||
| STRUCTURE - FRAME AND MEMBERS | |||
| 02/23/2010 | 154000 | ||
| Tl*the contact owns a 1999 hyundai sonata. he took the vehicle to the dealer for recall 09v124000 suspension front sub-frame. the vehicle was functioning normally prior to the repair. the vehicle currently doesn't drive straight and when he engaged the brakes it veered off of the road. he contacted the manufacturer. the manufacturer stated that they would not pay for the vehicle alignment. the failure and the current mileages were 154,000. | |||
| 02/23/2010 | 154000 | ||
| Tl*the contact owns a 1999 hyundai sonata. he stated that he took the vehicle to the dealer for recall 09v124000 suspension front sub-frame. the vehicle has not driven straight since the repair was performed instead it veers from side to side. he contacted the manufacturer who stated that hey would not pay for the alignment. the failure and the current mileages were 154,000. | |||
| 09/17/2009 | 99579 | 1 | |
| The lower control are separated from the frame on the front passenger side of the car as i was turning a corner, tearing up a brand new tire and the fender. *tr | |||
| 08/17/2009 | 134221 | 1 | |
| I have a 1999 hyundai sonata. today i took it in for an oil change and they noticed that the motor cradle is rusted out and needs to be replaced. in looking through the internet i have discovered that this is a consistent problem. | |||
| 03/14/2009 | 90126 | 1 | |
| While driving close to home my hyundai sonata 1999 started pulling to the right , getting more severe by the minute. i decided to go home. by the time i got home the front right wheel was leaning towards the outside of car. i took the wheel off and discovered that the lower front control arm separated from the frame because of severe corrosion in the sub frame of car. *tr | |||
| 02/08/2009 | 105000 | 1 | |
| 1999 hyundai sonata. driving down the highway at 65 mph and the right front passenger side of my car collapsed due to rusted sub frame which broke the axle and control arm. luckily no one was killed, but this was an alarming incident i have never experienced before with any car. this is dangerous. this is a serious problem. *tr | |||
| 01/01/2009 | 83000 | 1 | |
| Severe right side subframe rust problem on a 99 hyundai sonata nothing has been done to correct the problem . *tr | |||
| 11/13/2008 | 96398 | 1 | |
| Engine cradle (part of frame which supports front suspension) rusted through on front passenger side. frame failed while driving approximately five miles per hour. this failure damaged cv shaft. total repair bill was $1,270.00. *tr | |||
| 11/22/2008 | 119000 | ||
| Tl*the contact owns a 1999 hyundai sonata. for more than two months, the contact felt the vehicle pulling to the right. on november 11, 2008, while slowing down for a traffic light at 5 mph, the frame detached from the front end of the vehicle and the front passenger side tire bent. the contact noticed that the frame and tire bolts were corroded. the vehicle will be taken to the dealer for repair. the current and failure mileages were 119,000. | |||
| 10/21/2008 | 61000 | 1 | |
| My husband was driving my hyundai sonata 1999 with 61000 miles and suddenly the car was completely disabled. he was parked in the middle of the road. we call a tow truck and took the car to the mechanic. the mechanic said that he never ever ever saw a frame with so much rust and corrosion not even cars older and much miles than mine. the frame have holes all over. with all the extreme corrosion and rust the right sub frame is broken in half. the mechanic told me that he doesn't know how me and my children didn't have an accident because i'm the one who drives that car. after the mechanic saw my car we called another tow truck and we sent the car to the dealership. i'm waiting for a response from the dealership and see if hyundai will take responsibility of the damage this is causing me because i know that car is defected. in the meantime i don't have a car which gives a lot problems to me and my family. *tr | |||
| 09/22/2008 | 98723 | 1 | |
| Front subframe prematurely rusted and vehicle is not safe to use. *tr | |||
| 09/23/2008 | 80000 | 1 | |
| Hyundai sonata 1999 right side sub frame rusted and car became non drivable, took car to crown hyundai st pete fla for oil change, dealership advised that sub frame had rusted through, and advised to contact hyundai america for repair authorization at 1-800-633-5151 did this, current case #54326 car at dealership waiting for repair authorization from hyundai america. *tr | |||
| 07/17/2008 | 85000 | 1 | |
| I found that i could hardly control the steering of my car, and the tires were squealing even when going straight. i got the car to a shop and was told and shown that the sub frame has rusted through, making the car undriveable. i have contacted used parts dealers all over ny, nj and ma and have been told that this part is in high demand for my model car, because this seems to be a very common problem with this make and model car. despite this, hyundai dealers tell me it is not covered under their 10 year 100,000 mile warranty. it is a 9 year old car with 85,000 miles. *tr | |||
| 06/27/2008 | 80840 | 1 | |
| While driving the vehicle, there was a loud thump and it began pulling severely to the right. i drove it straight to my mechanic. he told me that there was a problem with the frames on hyundai sonata vehicles, and that mine exhibited the same kind of problems that others had reported. he said i was lucky i was not traveling on a freeway, as i could have lost control of the vehicle. the frame was badly rusted and. in his words, the frame was so bad i could not get bolts out of control arm, had to cut frame apart and press out bushings, replace sway link. the control arm was barely attached after the frame failed. he replaced the complete crossmember assembly (part #'s 62405-38101, 54561-38000, 265-2197) and suggested i follow up with hyundai, since this was a common problem. the repairs were finished on 7/2/2008. i contacted hyundai, provided all the information they requested and i was told they would get back to me within a week. i have talked with them several times, and each time i have been told a different story about why i have not been reimbursed yet. i have been in touch with several other people who have had their cars repaired by hyundai, or been reimbursed for repairs, and provided one person's case number as an example. as of 8/6/2008, i have yet to talk to the same person twice at hyundai, and i have not been reimbursed. the case number with hyundai's consumer department is 3340021. *tr | |||
| 08/15/2007 | 69000 | 1 | |
| I own a 1999 hyundai sonata. while driving 30 mph the passenger right side wheel collapsed and vehicle stopped. vehicle was towed to local mechanic and he stated that upper control arm was rusted from the inside out and the bolts separated from the frame. the vehicle was towed to the dealer and they were unable to diagnose the cause of failure. the current mileage was 69,000. it was clearly a manufacture defect. i made over 30 phones to try and resolve this matter i was prepared to go to the media with story. the manufacturer fixed my car after many weeks. i do feel that there should be a recall on this vehicle. *tr | |||
| 07/15/2007 | 80000 | 1 | |
| Took my vehicle to the dealership. upon inspection there was a rusted hole in the frame that went almost completely through the frame. i was told that hyundai would not repair the vehicle. i bought a new car and traded in the old vehicle, and was only given the minimum amount for a junk vehicle instead of the blue book value of several thousand dollars. *tr | |||
| 06/11/2008 | 136000 | ||
| Tl*the contact owns a 1999 hyundai sonata. while driving 40 mph at night, the contact slammed on the brakes to avoid running a red light. afterwards, she noticed that she could no longer place the vehicle into gear. the vehicle was inspected and the contact was informed that the frame on the front passenger side was rusted and detached from the vehicle. the vehicle was towed to the dealer and they stated that several other vehicles experienced the same failure. the dealer thought that the manufacturer would repair the vehicle for free and they faxed papers to them, but the contact has yet to receive any feedback from the manufacturer. the current and failure mileages were approximately 136,000. | |||
| 06/03/2008 | 152890 | 1 | |
| Vehicle was taken in for tire wear and squeaking/rubbing noise issue. the service station that checked it out, noticed the front part of the lower control arm was completely detached from the engine cradle/subframe. they said that the engine cradle/subframe had rusted out so bad that the control arm just ripped apart from it. only damage that was done is tire wear, but could of been worse if not caught in time. *tr | |||
| 09/15/2007 | 110466 | 1 | |
| Same issue as existing case # pe08029 1999 hyundai sonata was traveling on highway when passenger side front engine cradle support cracked and car became undrivable. *tr | |||
| 10/01/2007 | 135000 | 1 | |
| Last fall, driving along, all was fine, going only 15 mph, hit small bump, clunk, the front frame broke. the engine cradle as it is commonly called had rusted and broken through on the right side near the front wheel. the car sits undrivable still today. contacted hyundai consumer affairs - they were no help. *tr | |||
| 11/18/2007 | 123184 | 2 | 11/15/2007 |
| Hi, i bought my 1999 hyundai sonata from a private person nov.2007. i was driving the car to the store when all of a sudden the right front wheel went back into the wheel well. i had it towed to a garage to lift it to see what happened. the engine cradle was so rotted that my half shaft pulled out and broke. the control arm completely rotted off the cradle. this is what i can plainly see as a safety hazard. i could have had a wreck had i been going any faster. *tr | |||
| 11/22/2006 | 99500 | 1 | 02/18/2005 |
| Dt*: the contact stated while driving 50 mph, a small bump in the road was hit and the steering malfunctioned, causing the steering wheel not to work properly. the vehicle was towed to a service dealer, who determined that the sub frame was rotting. the manufacturer was notified. | |||
| 11/14/2006 | 109000 | 1 | 09/29/2003 |
| Dt*: the contact stated while driving 40 mph, there was a noise coming from the front right wheel area. upon inspection of the wheel, the wheel was observed to be angled slightly inward. the tread on the tire was also worn to the point of pressing the tread inward. the vehicle was towed to a service dealer, where it was determined that the sub frame was rusted, and had fractured due to the rust. the manufacturer was also notified. | |||
| 08/25/2005 | 63000 | 1 | |
| While driving my 1999 hyundai sonata( vin# kmhwf35v5xa04162) on south avenue in staten island the passenger side front wheel fell off.dealer said the cause was cracked k frame, then later upon asking for damage estimat said that it was due to bent k frame. since there was no accident involved decided to take car to my own mechanic. upon examination he showed methat the k frame was neither cracke nor bent, it was simply rusted throughout and the wheel assembly just fell off when the rust could no longer hold it to the frame.caleed back both deale and corporate hyundai not only for redress but also to examine for defect that could resulting injury to others in similar situation. their response was that the car was not under warrant for the k frame and that any problem whether due to rot, rust, or otherwise was not their responsibility. they would not send any service representative to examine the car period.if this incident had happened at highway speed it could have resulted in injury or death, hyundai's refusal to even take a time out to see if this is a real problem indicates a callous disregard for the safety of others who may be driving same make and model. the car is atill intact and available for whatever you might advise me to do with it. please respond as soon as possible as i can't leave it where it is forever. thank you very much annette hyland | |||
| STRUCTURE - FRAME AND MEMBERS - UNDERBODY SHIELDS | |||
| 11/20/2006 | 71000 | 1 | 02/09/2000 |
| Dt*: the contact stated while driving 60 mph on normal road conditions, the right wheel passed over a small dip in the road, and the vehicle began pulling to the right. the vehicle was lifted up, and it was noticed that the frame where the control arm was attached had rusted. the dealership was contacted, who suggested to bring the vehicle to a dealer for repairs. the manufacturer was also contacted, who informed the frame was not covered by the warranty. the vehicle remained inoperable after the incident. the contact expressed concern because the frame should be included in the vehicle's 100000 mile warranty. | |||