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 | |||
| 04/01/2010 | 1 | ||
| Re- 2001 hyundai sonata i was on way to work going 93 north towards boston 1 exit away from work when i went over 3 small bumps on highway nothing out of the ordinary, yet my tires felt as if they were not stable i was only going 60 slowed down to 30 took off ramp 1 block away from work, then completely stopped at a cross street intersection to take a right. i proceeded then i flew forward in my car. my car stopped short for a second i thought i hit my shifter in neutral or reverse, that was not the case, i was in drive. put car in park it made a searing ungodly sound i didn't know what was happening. i got out of my car just as two men came running over to help me. we noticed the tire completely against inside wheel frame. i just had a rim replaced not even 1 month ago and new brakes and tires yet i wasn't sure what this tire like that meant. i couldn't understand why i seem to be having to replace so many things, one right after another, however i was told after towing car to firestone that my whole car undercarriage frame subframe is completely rotted and that the axle is snapped and may even have damaged transmission i called hyundai to put a complaint in. they told me i have a recall on my car when they looked up my car by the vin yet i was never notified. they seemed quite caring and empathic to my situation, yet the last question they asked me, blew me away. christine the operator from hyundai asked me one more question ms.__ what do you plan to get out of this? are you kidding me? what a question, i asked if i should get a lawyer, and was it an voluntary or involuntary recall she said that hyundai put this recall into effects after the company realized and found that they may have a defective corrosive situation, yet on the web they were obviously investigated first then did something about it. she said recalls started in july of 09 and are still being issued to date, she said she'd mail me a packet to fill out and send back -oh joy!! cant wait. *tr | |||
| 07/28/2008 | 1 | ||
| Went to have my oil changed on my 2001 hyundai sonata and attendant told me my frame was badly rotting. he asked how long i was going to keep car because it could become a big problem. *tr | |||
| 05/19/2008 | 95000 | 1 | |
| Passenger side subframe rusted through and created a severe safety problem. my mechanics noticed it doing some work on my car. this must be addressed and something done before people are killed when these frames break. i was lucky it was discovered, because there is no warning lights for this... and can not be seen except if car is on a lift. *tr | |||
| 01/18/2008 | 1 | ||
| My 2001 sonata engine cradle is seriously rusted out on passenger side aft, a hole about the size of a softball. it's a safety issue and a recall should have be issued. i found multiple complaint online for the same auto. *tr | |||
| STRUCTURE - BODY | |||
| 08/20/2012 | 118000 | 1 | |
| The subframe has rusted out on the right side of vehicle causing it to no longer be drivable until the subframe is replaced. i was pulling into my driveway when the vehicle became inoperable because it turns out subframe had rusted through. *tr | |||
| 08/20/2012 | 118000 | ||
| The subframe has rusted out on the right side of vehicle causing it to no longer be driveable until the subframe is replaced. i was pulling into my driveway when the vehicle became inoperable because it turns out subframe had rusted through. | |||
| 01/03/2012 | 162000 | ||
| Tl- the contact owns a 2001 hyundai sonata. the contact stated that the underbody of the vehicle was rusted and caused fifty percent of the brake line was rusted. the dealer diagnosed that as a result of the under body rust, both the brake lines and the fuel lines were corroded. the dealer was in the process of repairing the under body, brake and fuel lines. the manufacturer assisted with the repair of the under body only and denied assistance with repairing the brakes and fuel lines. the failure and the current mileage was 162,000. kmj | |||
| 01/03/2012 | 162000 | ||
| Tl- the contact owns a 2001 hyundai sonata. the contact stated that there was corrosion on the under body of the vehicle, causing fifty percent (50%) of the brake to rust. the dealer diagnosed that as a result of the under body rust, both the brake lines and fuel lines had corroded. the dealer was in the process of repairing the under body, brake and fuel lines. the manufacturer assisted to repair only the under body, and denied repairing the brakes and fuel lines. the failure and current mileage was 162,000. nw | |||
| 09/05/2008 | 86000 | 1 | |
| While driving my 2001 hyundai sonata, my right front lower control arm broke off, separating my wheel / it collapsed. the tow truck driver told me this and showed me how severe the sub frame was corroded. it broke off, he never saw anything like it. please help. is this a recall that i didn't get? *tr | |||
| STRUCTURE - BODY - TRUNK LID | |||
| 08/01/2001 | 1 | 07/21/2000 | |
| Excessive dust entered the trunk through a vent and seeped through the passenger cabin.*jb....*ak | |||
| STRUCTURE - FRAME AND MEMBERS | |||
| 06/15/2010 | 120000 | ||
| Tl- the contact owns a 2001 hyundai sonata. the contact stated that while driving in a parking lot at 5mph the driver side front tire and wheel had seperated from the vehicle. a tow truck responded and informed the owner that the whole front end of the vehicle was rusted out. the vehicle is currently at a repair shop. hyundai informed the owner to have it towed to their dealership and they would repair it. the current and failure mileage is approximately 120,000. rd | |||
| 04/04/2010 | 131000 | ||
| I own a 2001 hyundia sonata. last night my daughter was driving the car and noticed the steering wheel was pulling very badly to the right. when i got a chance to look at it this afternoon i noticed the front right frame was almost completely rusted through. | |||
| 03/22/2010 | 166249 | ||
| Noticed an issue in january 2010: took car to a auto-repair shop for repair; new tires and alignment service. on 03/22/2010 while leaving a shopping mall the vehicle lost control and veared a hard left into a cement light pole in the middle of the parking lot. (i was able to apply the brakes in time and turn the vehicle) only damage was to the front driver side bumper and quarter-panel, body damage only. i then tried to drive the vehicle which at that point operated in drivable condition. on my way to the auto-repair (less then 1 mile away) my vehicle completely broke down in the middle of an intersection in another shopping plaza. the car was then towed to the auto-repair shop, which then later called and explained that the frame of the car was cracked and the whieel was detatched. i called the dealership and they took the matter very lightly telling me to just bring the car in (the vehicle was not drivable). i call my towing company and towed the vehicle to the dealership and now awaiting response. i was not offered a loaner, nor did the manager know of any recall, neither did i, something i had to investigate for myself. (luckily i was not on the highway when this happen or i would not be here today. | |||
| 10/23/2009 | 98000 | ||
| Tl* the contact owns a 2001 hyundai sonata. while driving the vehicle would drift towards the right. upon further inspection he discovered that because the right side of the sub-frame was corroded , it caused the engine to tilt towards the right. he was in the process of contacting the dealer and the manufacturer. the current and the failure mileages were 98,000. the vehicle identification number was unavailable. | |||
| 10/05/2009 | 147609 | 1 | |
| I was driving and the tire fell off the front frame from being rusted. *tr | |||
| 09/03/2009 | 68912 | 1 | |
| I was driving down the street and the frame snapped on the front right hand side luckily there was not an accident. this should be a recall on the vehicle its an 01 with 68,000 miles.*tr | |||
| 07/30/2009 | 140000 | ||
| Tl*the contact owns a 2001 hyundai sonata. while replacing the tires on the vehicle, the contact noticed that the alignment was not gripping correctly. he examined underneath the vehicle and noticed that the frame on both of the front wheel suspension mounts were rusted. the vehicle has not yet been inspected by a mechanic. through online research, the contact discovered that this was a very common failure with his type of vehicle. he believes that a recall should be issued by the manufacturer. the current and failure mileages were 140,000. | |||
| 07/17/2009 | 91200 | 1 | |
| I took my car to a mechanic today to have the brake pads replaced and he found a corroded hole in the sub-frame assembly. he mentioned this was recalled by hyundai last year but i was never notified of such a recall and i'm upset as this could have caused a very serious accident. why was i not notified of the recall first of all, and what is hyundai going to do to fix my car? *tr | |||
| 04/24/2009 | 120762 | 1 | |
| I own a 20001 hyundai sonata. i took it to the repair shop for a front end alignment because the car was pulling badly to the right and was informed that the subframe on the right front is severely rusted. it was recommended that i not continue to drive this car because it is extremely dangerous to do so. *tr | |||
| 02/28/2008 | 141000 | 1 | |
| Tl*the contact owns a 2001 hyundai sonata. the contact heard an abnormal noise near the rear of the vehicle. the dealer stated that the subframe had excessive corrosion and needed to be replaced at the cost of $800. her state was not included in nhtsa campaign id number 09v124000 (suspension). the vehicle has not been repaired. the failure and current mileages were 141,000. updated 05/04/09 *bf updated 05/04/09.*jb | |||
| 04/10/2009 | 89300 | ||
| Tl*the contact owns a 2001 hyundai sonata. the contact took her vehicle to a local service station and was advised by a technician that the front subframe had excessive corrosion. she called the manufacturer and filed a complaint. the contact is currently waiting for a response. the failure and current mileages were 89,300. | |||
| 04/13/2009 | 99925 | 1 | |
| Was told by mechanic that my frame is rotting out. has holes size of golf ball not to mention lines 5-6 of rot. mechanic informed me that he will no longer work on the car as it is too dangerous for me to drive it and suggests i get a new car. *tr | |||
| 04/09/2009 | 149000 | 1 | |
| The car was pulling to the right and thought i needed a wheel alignment but after coming back from taking my children to school the car stopped in front of my house and started making a rattling sound when i put it in gear (reverse and drive ) i thought is was axle that may have slipped out of place. the car was taken to mechanic who said i had a lot of rust and a whole in my frame and the rust started to fall off the car frame. i called the consume affairs dept for hyundai and they picked up the car and took it to a hyundai dealership to hopefully get fixed. they wanted to charge me $2,100.00 for the repairs. *tr | |||
| 08/30/2008 | 124000 | 1 | 05/01/2001 |
| Tl*the contact owns a 2001 hyundai sonata. while driving approximately 55 mph on normal road conditions, the contact heard a loud noise outside of the vehicle. the engine began to reduce power without assistance. there were no warning indicators illuminated on the instrument panel. the vehicle was driven cautiously to an authorized dealer for inspection and they replaced the frame cross member assembly and speed sensor. the failure mileage was 124,000 and current mileage was 130,000. updated 04-23-09 *bf updated 04/30/09.*jb | |||
| 03/23/2009 | 1 | ||
| Vehicle steering wheel started to unalign counter clockwise in the last week,then a noise from the front right wheel, then my wife pulled into the garage when i noticed the front passenger wheel on a tilt. i looked under the car and there is a huge 4 hole of rust right through the frame. *tr | |||
| 03/23/2009 | 112300 | 1 | |
| I was driving down the road at 30mph and the car started swerving left and right like 'crazy'. i pulled over and noticed the drivers side front wheel was bent even though wheels were straight. i looked underneath the car and there was crack all the way through the subframe of the car where the lower torque arm attaches to the wheel. the torque arm looked fine but where it attached was rusted so much it broke. i touched this area and noticed a fist sized hole of metal had rusted away. hyundai apparently used very cheap metal when building their product. i checked the other side and noticed the same problem. the other front wheel side is about ready to break too and fall off the car. i managed to make it home trying my best to stay in one lane which was very hard and didn't always do that. i will take some pictures later. *tr | |||
| 03/24/2009 | 116000 | 1 | |
| In february i had gone to have my oil changed by my uncle who works at a shop in franklin he had put my car up on the lift and looked it over to ensure there wasn't any major problems in which he concluded there was not. on march 20th 09 i went to pep boys to have 4 new tires put on and an alignment done. on march 24th i was driving my son home and notice the car was making a odd noise and figured i should get it looked at. i went home and about an hour later i went to pull out of the driveway to take my car to my uncles shop when i heard a terrible loud noise so i put the car in park the conclusion was that my axle broke off and my subframe was completely rotted and my engine was almost on the ground. *tr | |||
| 03/12/2009 | 1 | ||
| 2001 hyundai sonata bought less than 4 years ago has severe rotting in the subframe. mechanic says it is extremely dangerous and considers it a deathtrap. i've had one problem after another since i bought this car and i just don't understand why this car hasn't been recalled as of yet. so many people have experienced many of the same problems with this model it is appalling. i am completely disgusted in the fact that this degree of rot does not happen in 3 years and most definitely was sold to me this way. i was not told by the dealer of any rot in the subframe when i purchased this vehicle, how is that legal??? something needs to be done about the all to common problems with this car or do people have to lose their lives in an accident before this is taken seriously? *tr | |||
| 03/23/2009 | 108000 | 1 | |
| I have a 2001 hyundai sonata. i just bought new tires for my car and wanted them to do an alignment as i thought it really needed one. come to find out from the mechanic, my car is unsafe to drive because my engine cradle (sub frame) is completely rusted in half which was throwing off my alignment. i see that there have been many complaints about this exact same thing, why has this safety issue not been recalled? *tr | |||
| 03/18/2009 | 89000 | 1 | |
| 2001 hyundai sonata frame rusted at front swing arm, both sides. 109k miles. *tr | |||
| 03/12/2009 | 111550 | 1 | |
| I hit a pothole and the right front began to pull, upon taking the car to a repair shop the found that the front subframe was rotted through on there right side and almost as bad on the left side. *tr | |||
| 02/27/2009 | 85000 | 1 | |
| The car was sitting in the parking lot and when we went out to start the engine it turned over but it wouldn't move so we towed it to a local goodyear repair garage where they report that the undercarriage has rusted through and the motor dropped and bent the axle. they cannot find a used undercarriage that isn't rusted through. we have reported this to hyundai consumer affairs and they have given us a case number (3122110) but report that this car has not been recalled. *tr | |||
| 01/31/2009 | 1 | ||
| I have a 2001 hyundai sonata i purchased in 2005 used from a toyota dealership, and didn't have a warranty on the car. i took it in to my local garage in january 2009 so they could check out a noise my car is making. they said that when they put it up on the lift, they saw that my cradle is severely rusted and that my car will not pass inspection in june and replacing it would be about the cost of my car. i have researched online and found that many others are having the same problem. hyundai should have made a recall so i don't have to purchase a new car right now. thank you. *tr | |||
| 02/12/2009 | 142000 | 1 | |
| Underframe of 2001 hyundai sonata rusted right through. *tr | |||
| 02/01/2009 | 106588 | 1 | |
| While making a right hand turn the drivers side lower control arm tore out of sub frame causing vehicle to pull out of control into oncoming traffic lane. both axles were destroyed. hyundai will pay for frame replacement but no other costs. the axles , 2 tows. 1 to my home the 2nd to dealership or the car rental that they arranged and originally said they pay for. my case manager will not take my calls nor will anybody explain why they wont pay for the damages there own dealer said was caused by defective frame. *tr | |||
| 08/01/2008 | 85000 | 1 | |
| I have noticed that the engine cradle has rusted on my 2001 hyundai sonata. it only has 85k miles. this seems to be a manufacturing defect to me. i first noticed it when i got new tires, there was a slight pull to my car. i brought it in for alignment and was told it was useless to go through with the alignment due to the engine cradle being rusted out. since then i have put my car out and have had to ride my motorcycle to and from work since i do not have the money for repairs. *tr | |||
| 01/23/2008 | 160000 | 1 | |
| Front right portion of front subframe is rusted and broken. alignment and steering is way off . was advised not to drive since frame damage is extremely dangerous. *tr | |||
| 09/07/2008 | 710000 | 1 | |
| Both tie rod ends break. replaced both. car then experienced broken left axle and lower control are which was attributed to crack in sub frame. sub frame replace with axle and control arm. are there any recall on subframe for 2001 hyundai sonata gls? car has not experience any front end collision in history of ownership of vehicle. car bought new at dealership. *tr | |||
| 12/10/2008 | 117000 | 1 | |
| 2001 hyundai sonata v6, with under 120k miles. tires replaced for wear and alignment performed on week of 12/08/2008. mechanic pointed out alignment a moot point due to right sub frame, aka k-frame,aka engine frame, aka right wheel suspension mount was rusted through to point of being able to enter rust cavity with all fingers. this resulting to cracked subframe at wheel well side were suspension is mounted. some complainants report leaking power steering line from overextended distance from frame stretch . this also is a problem in sante fe. i imagine the same k frame being used a cost saving measure. i'm now waiting for hyundai america to respond to my case #3460531. don't you believe anyone who discounts this as being out of warranty. this is not cosmetic body rust through , but a major safety issue and nhtsa will be issuing a recall once the body bag counts begin being attributed to this national problem. some reps are saying it's a salt belt sales problem but this consists of 60% of their sales and they are going to have to make good for poorly engineered steel construction. it appears the salt water entered front of frame but never could exit due to no exit holes towards rear of frame. oxygen exposure took care of the rest. *tr | |||
| 12/05/2008 | 1 | ||
| I took my 2001 hyundai sonata for an oil change and my mechanic showed me that there is a fist-sized hole in the front right sub frame under my car. currently, i do not have the funds to fix my vehicle and it will not pass inspection the next time around. i would like hyundai to pay for this damage because a vehicle that is only 7 years old should not be rusting out! *tr | |||
| 11/24/2008 | 11100 | 1 | |
| Driving 2001 sonata car was swaying on road when going on turns was not working with steering in timely manner. had mechanic look at to see what was wrong. he found on passengers side of car the lower frame rusted from inside out where the lower control arm attaches and is now only semi attached so the assembly moves around. there is a huge hole in frame. car is no longer safe to drive as whole assembly will fall off. as you can see car is only 7 years old. this is unacceptable car only has 111000. miles on it. the car is in my driveway has not been taken apart all parts are original not sure what to do. can't be driven as is. i noticed other complaints of same nature i don't consider this condition acceptable in a 7 year old car frames should last many more years. *tr | |||
| 11/19/2008 | 114000 | 1 | |
| I purchased my 2001 hyundai sonata gls v6 in 2002 and have had nothing but problems from it, but this is the worst so far. my car started jerking terribly when i hit any kind of bump or uneven pavement and my steering wheel was off center when driving straight. i had someone look underneath the car and noticed the frame was rotting, therefore i was driving it to my mechanic and as i pushed the brake to stop, the right/front wheel separated from the frame/axle. there was corrosion on the frame around the axle. i called hyundai and they gave me a claim # and said someone would contact me within 3-5 business days, so we will see. *tr | |||
| 11/11/2008 | 117000 | ||
| Tl*the contact owns a 2001 hyundai sonata. the contact stated that the vehicle was driving poorly and she took it to a mechanic. after inspecting the vehicle, the mechanic stated that either the undercarriage or the frame was rusted. the dealer repaired the vehicle for free. the failure mileage was 117,000. | |||
| 10/24/2008 | 158000 | 1 | |
| 2001 hyundai sonata- rust is on the front sub-frame and we were told by a mechanic that it was highly dangerous to drive because the wheels will become detached at any bump along the road. the steering is also jerky and the steering wheel is not straight anymore and the two front tires are pointing inward and wearing very fast on the inner most part of the tires. is there some type of recall or investigation going on for this matter? are there other complaints on the same model of car as mine? is there any compensation that is due to me? we have heard from a friend that there was an investigation going on with this matter (nhtsa number pe08029) please get back to me asap. thank you. *tr | |||
| 10/11/2008 | 1 | ||
| Drove over a crack in the road, felt and heard snapping, took to mechanic, was told right subframe rusted out so bad that it snapped. *tr | |||
| 09/23/2008 | 82000 | 1 | |
| 2001 hyundai sonata with 82,000 mile sub frame (cradle) rusted thru causing control arms to push thru cradle. car was all over and off the the road. *tr | |||
| 09/19/2008 | 92500 | 1 | |
| 2001 hyundai sonata gls - the vehicle sprang a leak underneath of steering fluid. i took it to my local mechanic he put it up on the lift, found a problem with the subframe being so weak and rusted that we can't drive it. my mechanic called a local hyundai dealer who said the whole problem was covered (incl steering leak caused by bending subframe). i then towed it to where i bought it from and they called to tell me i needed to prebuy over $2000, subframe not covered. hampton hyundai, new hampshire, 177 lafayette road. i found two other dealerships who say both problems should be covered. i am original and present owner, under 93,000 miles. *tr | |||
| 09/17/2008 | 77095 | 1 | |
| I was driving my 2001 hyundai sonata a car i bought new in florida and has always been in florida. my engine carriage rusted through and snapped the control arm on my car and the entire wheel came off sending me into two lanes of oncoming traffic. it was taken to hyundai dealership i am waiting to hear if hyundai will repair the huge damage to my car. not to mention i was almost killed due to this catastrophic failure. the nhtsa needs to take action on this now. lives are at risk. it is a catastrophic failure. *tr | |||
| 09/05/2008 | 86000 | 1 | |
| While driving my 2001 hyundai sonata, my right front lower control arm broke off, separating my wheel / it collapsed. the tow truck driver told me this and showed me how severe the sub frame was corroded. it broke off, he never saw anything like it. please help. is this a recall that i didn't get? *tr | |||
| 08/26/2008 | 112343 | 1 | |
| My 2001 hyundai sonata's subframe rusted to the point of where there were 7 in holes completely through- this caused the lower swing arm to detach from the frame and subsequently the vehicle suspension failed. this occurred while my two children were in the car. both front tires were damaged. dealer did not replace tires, did not pay for towing or alternate transportation- gary rome hyundai, holyoke ma. *tr | |||
| 08/13/2008 | 74058 | 1 | |
| In 2007 a routine oil change was being performed on the car and it was noticed that there was a 1-2 inch rotted hole the right side subframe. local mechanic said there weren't any recalls, so he welded on a new piece of metal for support. today (8/13/08) another oil change was being done and it was noticed that there is now a 2-3 inch hole on the left side subframe that wasn't visible a year ago. mechanic highly recommends replacing the front subframe. ref pe08029. *tr | |||
| 08/05/2008 | 166500 | 1 | |
| Tuesday, august 5, 2008, i brought in my 2001 gls v6 hyundai sonata to balise hyundai of cape cod in hyannis, ma. my car had approximately 166,500 miles on it at this time. i was looking to get a throttle position sensor replaced. during their diagnostics, with the car on a lift, they noticed two things. one, a power steering leak was occurring most likely because of a corroded power steering line near the passenger side of the subframe. two, in the immediate area of the suspected hose failure, the subframe had rusted through on two sides of the piece. the main hole in the subframe is fist-size or larger and the second is not good. i was informed that the subframe issue was a major safety hazard and warned me of what could happened should it fail. they also told me about the difficulties that replacing it could bring. they told that they were highly uncomfortable with me driving off the lot with the car with the subframe in that condition because it could go at any time. when they gave me an estimate for repairs to my car, they informed me that they might do the service on the subframe for free. they had to get approval from a regional rep or such person. however, as of today, sunday, august 10, i have not heard back from the dealer. today, i decided to do some research into replacing the subframe and finding the part. when i did a yahoo! search for sonata subframe, i came across the nhtsa investigation into this problem. i, thankfully, have not had a failure or accident because of this condition, yet. *tr | |||
| 08/01/2008 | 79000 | 1 | |
| Took automobile for routine maintenance. mechanic discovered major rusting on subframe and engine cradle. rusted through and has been described as extremely dangerous. *tr | |||
| 07/10/2008 | 1 | ||
| While changing the oil a large hole in the right side of the frame where the front suspension connect to was found. it is all rusted through. i was told not to drive the car by the mechanic. i have attempted to get a new part from the junk yard and the three replacements they found were rusted in the same place. i called the hyundai dealer and they said it was around $1500.00 to fix the problem. i called their customer care to find out if there was a recall and they said not at this time. *tr | |||
| 06/21/2008 | 65000 | ||
| Tl*the contact owns a 2001 hyundai sonata. while driving approximately 15 mph, the front passenger side wheel collapsed. the vehicle had to be towed to a mechanic and a baseball size hole in the subframe was discovered, which caused the tie rod to dislodge. the mechanic also discovered two more holes in other areas of the subframe. the current and failure mileages were 65,000. | |||
| 05/19/2008 | 95000 | 1 | |
| Passenger side subframe rusted through and created a severe safety problem. my mechanics noticed it doing some work on my car. this must be addressed and something done before people are killed when these frames break. i was lucky it was discovered, because there is no warning lights for this... and can not be seen except if car is on a lift. *tr | |||
| 05/01/2008 | 128500 | 1 | |
| While rounding a gradual curve at approximately 50mph suddenly lost steering control and went off road. examination of vehicle subsequent to the accident revealed loss of control caused by severely rusted right (passenger side) front subframe and approximately 8 inch hole and bending/cracking of such due to the rust, this on a vehicle which is otherwise pristine (there is absolutely no rust elsewhere on the vehicle). i urge nhtsa to require hyundai to address what i have now learned is a very common problem with the model in question, especially before any other lives are put in jeopardy or lost due to what is clearly and obviously a gross manufacturing and/or design defect. note that i consider the situation to constitute no less than an emergency and that until certain model years of the hyundai sonata are updated with a revised/new subframe they should not be driven and indeed are not safe to be driven. at present my vehicle is no longer road worthy due to the rusted subframe and as it is 4 months out of warranty (warranty pertaining to rust through) i foresee that i will have to bear the expense of the repair (subframe replacement) myself. *tr | |||
| 09/28/2007 | 90426 | 1 | 09/01/2006 |
| 2000 hyundai sonata with a defective sub frame. consumer would like to be reimbursed for expenses on the repair of the sub-frame. he also believes that hyundai needs to put out a recall on them and get them fixed due to concerns with the sub-frame.*kb the consumer stated as he was driving, the lower control arm of the front passenger wheel disconnected from the vehicle which caused him to slide to an immediate halt. the cause of the failure was due to a poorly designed frame which rusted and rotted so badly that the control arm had fallen off the frame, the axle ripped from the transmission and the wheel had slammed into the wheel housing and quarter panel. the insurance company declared the vehicle a total loss due to the extent of the damage prior to the frame damage, the consumer experienced a flat tire which was due to excessive wear on the inside of tire. *jb | |||
| STRUCTURE - FRAME AND MEMBERS - UNDERBODY SHIELDS | |||
| 08/01/2012 | 82142 | 1 | |
| I bought this used 2001 sonota from a local guy who rebuilds cars for resale. i understood that it came with a salvaged title. however, i was assured that the vehicle was safe to operate. six weeks, 4,000 mi. later i hit a pot whole on my street and damaged the steering. i took it to a local repair shop and discovered the r-side sub-frame was broken due to corrosion. who is responsible for allowing a vehicle that has a possible r-side sub-frame recalled, to never get fixed and placed back on the road? fortunately, it broke at a low speed in front of my house. *tr | |||
| 08/31/2007 | 83949 | 1 | 10/18/2000 |
| Tl*the contact owns a 2001 hyundai sonata. while changing the oil in the vehicle, the contact noticed that the sub frame near the engine was corroded. he touched the sub frame and his hand went straight through. the vehicle was taken to a dealer and they stated that he lived in a rust belt and discovered that the control arm was held in place by only one bolt. the vehicle was repaired by taking a sub frame from a salvaged vehicle. the current mileage was 83,959 and failure mileage was 83,949. updated 12/12/2007 *bf updated 12/12/07 *tr | |||