Recalls
| Campaign | Manufacturer | Manufacturing date | Type | # of units affected | Date Owner notified Mfg | Recall Initiated by | Manufacturers of recalled vehicles/products | Report Recieved Date | Record Creation Date | Regulation Part Number | FMVSS Number | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| SUSPENSION | ||||||||||||||||
| 09V124000 | HYUNDAI-KIA AMERICA TECHNICAL CENTER INC | from 09/15/1998 to 11/20/2003 | V (Vehicle) | 188282 | 07/17/2009 | ODI | HYUNDAI MOTOR COMPANY | 04/16/2009 | 04/16/2009 | |||||||
| Defect Summary | Hyundai is recalling 188,282 my 2001-2004 sonata and my 2001-2004 xg300 and xg350 vehicles originally sold in or currently registered in the states of connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia. road salt applied in these jurisdictions during the winter months may result in progressive, internal corrosion of the front sub-frame on the vehicles, and may result in thinning or perforation of the sub-frame steel. the corrosion is frequently visible and often discovered during inspection or routine maintenance, and owners may also hear noises or notice tire misalignment and steering pull. if these signals are undetected or unheeded, the corrosion may progress and the forward mounting of the lower control arm may detach from the sub-frame. | |||||||||||||||
| Consequence Summary | If that happens, the vehicle may lose drive power to the wheels, and the front wheel may make contact with the fender or wheel well, thereby increasing the risk of a crash. | |||||||||||||||
| Corrective Summary | Dealers will measure the thickness of the front sub-frame and inspect the front sub-frame for corrosion damage and, if necessary, the front sub-frame will be replaced with a new sub-frame that incorporates additional holes in the upper and lower panels. if the front sub-frame does not require replacement, the dealer will add drainage holes to the sub-frame and will treat the sub-frame with rust-proofing material to stop the corrosion process. this procedure will be performed free of charge. the recall is expected to begin during april 2009. owners may contact the hyundai customer assistance center at 1-800-633-5151. | |||||||||||||||
| Notes | Hyundai recall no. 089.owners may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov . | |||||||||||||||
Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| SUSPENSION - FRONT - STABILIZER BAR | |||||
| 0250007 | 05/01/2002 | 633853 | Subject regarding rear stabilizer bar bushing replacement-noise repair procedure. *jg | 09/25/2002 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| SUSPENSION | ||||||
| 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. | ||||||
| SUSPENSION - FRONT | ||||||
| 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. | ||||||
| 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. | ||||||
| SUSPENSION - FRONT - CONTROL ARM | ||||||
| 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. | ||||||
| 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. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| SUSPENSION | |||
| 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 | |||
| 08/01/2012 | 82142 | ||
| 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. | |||
| 11/24/2011 | |||
| I inspected under the hood and noticed several large holes rusted through the engine cradle. i have read that there is a recall on this component and noticed that several people have had near fatal accidents because of this issue. | |||
| 06/01/2011 | 120000 | ||
| Tl- the contact owns a 2001 hyundai sonata. the contact stated that there was rusting in the sub-frame of the vehicle. the dealer and manufacturer were notified and informed the contact that his vin was not apart of the nhtsa campaign id number: 09v124000 (suspension) recall. the failure was not repaired. the failure mileage was 120,000 and the current mileage was 124,000. nw | |||
| 12/04/2009 | 116000 | 1 | 03/06/2005 |
| Tl* the contact owns a 2001 hyundai sonata. while driving he noticed that the passenger front tire was misaligned with the vehicle. the vehicle was taken to a local repair facility for inspection. the mechanic concluded that the front sub frame was corroded, and that this condition could cause the lining to thin. he filed report number 3787345 with the manufacturer. he was advised by a representative that his vehicle identification number was excluded from recall #09v124000 (suspension). the vehicle was in the process of being repaired at an expense of $1,150,000 .the vehicle identification number was unavailable. updated 01/12/10. *lj updated 01/13/10.*jb | |||
| 09/29/2009 | 136000 | 1 | |
| Complete failure of brake system due to rust and corrosion of brake lines. the 2001 hyundai sonata lines came apart due to rust. reported incident to hyundai consumer affairs and was told it would be covered under recall notice dated: 4-14-09 id# 09v124000 action# ea08016, which included quality issues with cars suspension due to rust and corrosion. was notified by dealer today that hyundai was not covering the defective brake lines, because it was not specifically called out in the recall. fortunately, my son and i were in a parking lot when the brake failure occurred, pedal went all the way to the floor and fluid leaked out of the brake line, which had rusted through. i'm not sure of the scope of this defective, but obviously had we been on the freeway this could have been a life or death experience. thankfully god was watching over us. please investigate similar brake failures on this vehicle. also if there is anything that can be done to help us resolve this matter we hyundai it would be greatly appreciated. *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 | |||
| 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 | |||
| 03/01/2002 | 1 | ||
| A squeaking noise is coming from the rear of the vehicle. now the noise has went from a squeaking to a roaring noise. the dealership is aware of the problem. nlm | |||
| SUSPENSION - FRONT | |||
| 03/21/2011 | 130000 | ||
| Tl* the contact owns a 2001 hyundai sonata. the contact was traveling 30 mph when the frame buckled and the front wheels began collapsing outward. the contact stated that the vehicle had been drifting from side to side for some time when the vehicle was being driven. the vehicle was not inspected or repaired. the vin was unavailable. the failure and current mileages were 130,000. | |||
| 03/21/2011 | 130000 | ||
| Tl- the contact owns a 2001 hyundai sonata. the contact was traveling 30 mph when the frame on the vehicle buckled and the front wheels started pointing outward. the contact stated the vehicle had been drifting from side to side for some time when the vehicle was being driven. the contact had not had the vehicle inspected at the of the complaint. the vin was unknown. the failure mileage and current mileages was 130,000.rl | |||
| 10/07/2010 | 75000 | ||
| Tl- the contact owns a 2001 hyundai sonata. while traveling 40 mph the contact noticed that the vehicle had suddenly began to shutter and pull to the right of the street. after examining the vehicle the contact noticed that the front passenger side axle had broken due to rust. the vehicle has not been diagnosed and there were no prior warnings. the current and failure mileages were 75000. bml | |||
| 06/25/2009 | 73000 | 1 | |
| After recently purchasing a used 2001 hyundai sonata, i noticed an excessive amount of rust / corrosion on the engine cradle and sub - frame. vehicle has only 74000 miles on it but does not appear as if it will last much longer. i am able to poke my fingers through the metal and pieces fall out of the steel assembly. *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 | |||
| 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 | |||
| SUSPENSION - REAR | |||
| 06/14/2003 | 45000 | 08/14/2001 | |
| Right-rear (i.e., passenger side rear) tire wearing abnormally. rotating tires has spread the problem to all tires mounted at any time on the right-rear. nothing has happened to damage any suspension components and right-rear wheel alignment is okay. *nlm | |||