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2003 Hyundai Santa Fe

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Hyundai Santa Fe do not stand out strongly from the model-year median of 212.5.

About this comparison →

When problems were reported

Mileage at the reported incident

245 reports with mileage · 63 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Suspension. Review the 56 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Air Bags. Review the 42 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 35 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

26 crash reports5 fire reports17 injury reports

What owners actually said

308 reports
103,000 miles · Apr 15, 2013
Service Brakes

I HAD NEW BRAKE PADS AND ROTORS PUT ON MY CAR LAST YEAR 2012 BECAUSE THE BRAKE SHOE FELL OFF ON THE DRIVERS SIDE. I BEGAN TO HAVE A SCRAPPING NOISE IN MARCH 2013 AND THEN ON APPROXIMATELY MARCH 22, 2013 WHEN I WAS RETURNING FROM THE DOCTOR'S OFFICE MY CAR SEIZED WHEN I WAS AT A STOP. IT WOULD NOT MOVE FORWARD AND I COULD NOT T…

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I HAD NEW BRAKE PADS AND ROTORS PUT ON MY CAR LAST YEAR 2012 BECAUSE THE BRAKE SHOE FELL OFF ON THE DRIVERS SIDE. I BEGAN TO HAVE A SCRAPPING NOISE IN MARCH 2013 AND THEN ON APPROXIMATELY MARCH 22, 2013 WHEN I WAS RETURNING FROM THE DOCTOR'S OFFICE MY CAR SEIZED WHEN I WAS AT A STOP. IT WOULD NOT MOVE FORWARD AND I COULD NOT TURN. TWO GUYS CAME TO ASSIST ME TO PUSH ME TO THE SIDE OF THE ROAD AND THE CAR WOULD NOT BUDGE. I HAD MY CAR TOWED TO GOODYEAR IN SCHENECTADY. I NEEDED TO REPLACE MY BRAKE PADS, ROTORS, AND PISTONS. THE REPAIR COST $476.00. THE CAR IS NOW MAKING A SCRAPPING NOISE AGAIN. I HAVE READ MULTIPLE COMPLAINTS REGARDING THE BRAKES FOR THIS CAR AND I BELIEVE THAT HYUNDAI OR THE STATE AUTHORITY SHOULD MAKE A RECALL FOR THE BRAKES, AND ASSOCIATED PARTS. I WOULD LIKE TO BE REFUNDED THE REPAIR COSTS FOR LAST YEAR AND THIS YEAR. *TR

NHTSA ODI #10508315

98,000 miles · Apr 13, 2013
Suspension

A COUPLE OF YEARS AGO, I SAW THE RECALL ON THE REAR SUSPENSION ON 03 HYUNDAI SANTA FE. SO I WENT TO TWO DEALERS AROUND MY AREA AND ASKED THEM TO CHECK THE CONDITION. ONE OF THEM DID NOT EVEN RESPONDED TO MY QUESTION AND RETURNED THE CAR, AND ANOTHER ONE SAID THEY ARE FINE AND NOT NEED TO BE EITHER TREATED OR REPLACED. THEN A…

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A COUPLE OF YEARS AGO, I SAW THE RECALL ON THE REAR SUSPENSION ON 03 HYUNDAI SANTA FE. SO I WENT TO TWO DEALERS AROUND MY AREA AND ASKED THEM TO CHECK THE CONDITION. ONE OF THEM DID NOT EVEN RESPONDED TO MY QUESTION AND RETURNED THE CAR, AND ANOTHER ONE SAID THEY ARE FINE AND NOT NEED TO BE EITHER TREATED OR REPLACED. THEN A FEW DAYS AGO, JUST WEB SURFING THE WEB AND FOUND THE SYMPTOMS OF THE PROBLEM OF THE REAR TAILING ARMS RECALL. MY CAR HAS ALL THAT SYMPTOMS RIGHT NOW, BUT HYUNDAI IS TELLING ME THAT MY VEHICLE IS NOT EQUIPPED WITH THE FAULTY TRAILING ARMS, AND MY VEHICLE IS NOT QUALIFY FOR THE RECALL. MY CAR SWING WHEN I MAKE TURNS WEIRDLY. IT FEELS LIKE YOU HAVE A LOOSE TRAILER IN THE BACK. ALSO THE HEIGHT OF THE CAR HAD BEEN LOWERED, AND ALSO WHEN I GO OVER A SPEED BUMP, I HEAR CREAKING SOUND. I HAVE REPLACED THE FRONT STRUTS, STRUT MOUNTS, AND REAR SHOCKS SO THEY ARE NOT COMING FROM THOSE. *TR

NHTSA ODI #10508136

120,000 miles · Jan 22, 2013
Suspension

TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO HAVE NHTSA CAMPAIGN ID NUMBER: 09V123000 (SUSPENSION: REAR) PERFORMED FOR RUST ON THE TRAILING ARMS. THE CONTACT STATED THAT THE RECALL REPAIR WORKED FOR THE REAR PASSENGER SIDE BUT WAS INFORMED BY A PRIVATE MECHANIC THAT IT APPEARED T…

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TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO HAVE NHTSA CAMPAIGN ID NUMBER: 09V123000 (SUSPENSION: REAR) PERFORMED FOR RUST ON THE TRAILING ARMS. THE CONTACT STATED THAT THE RECALL REPAIR WORKED FOR THE REAR PASSENGER SIDE BUT WAS INFORMED BY A PRIVATE MECHANIC THAT IT APPEARED THAT THE DEALER DID NOT REPAIR THE REAR DRIVER SIDE OF THE VEHICLE. THE CONTACT WAS ALSO INFORMED THAT THE VEHICLE COULD NOT BE DRIVEN BECAUSE THE REAR WHEEL AND FRAME OF THE VEHICLE WAS COMPLETELY RUSTED. THE FAILURE MILEAGE AND CURRENT MILEAGES WERE 120,000. THE VIN WAS NOT AVAILABLE.

NHTSA ODI #10493721

70,000 miles · Jan 16, 2013
Vehicle Speed ControlCrash

TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT WHILE PARKING THE VEHICLE AND APPLYING THE BRAKES, THE VEHICLE ACCELERATED AND CRASHED INTO A BUILDING. THE CONTACT WAS NOT INJURED HOWEVER, A POLICE REPORT WAS FILED OF THE INCIDENT. THE VEHICLE WAS NOT INSPECTED FOR THE CAUSE OF THE ACCELERATION FAILURE. THE…

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TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT WHILE PARKING THE VEHICLE AND APPLYING THE BRAKES, THE VEHICLE ACCELERATED AND CRASHED INTO A BUILDING. THE CONTACT WAS NOT INJURED HOWEVER, A POLICE REPORT WAS FILED OF THE INCIDENT. THE VEHICLE WAS NOT INSPECTED FOR THE CAUSE OF THE ACCELERATION FAILURE. THE MANUFACTURER WAS NOT CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 70,000.

NHTSA ODI #10493246

128,010 miles · Dec 23, 2012
Suspension

I PURCHASED A USED 2003 HYUNDAI SANTA FE FOR MY SON WHICH HE TOOK TO COLLEGE. DURING WINTER BREAK, I TOOL IT TO A LOCAL HYUNDAI DEALER TO HAVE A COMPLETE TUNE-UP, AS WELL AS CHECK A CREAKING SOUND IN THE LOWER LEFT REAR AND A "POP" SOUND WHEN DECELERATING. THE DEALER INFORMED ME THE LOWER REAR LEFT TRAILING ARM IS BAD AND NEEDS…

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I PURCHASED A USED 2003 HYUNDAI SANTA FE FOR MY SON WHICH HE TOOK TO COLLEGE. DURING WINTER BREAK, I TOOL IT TO A LOCAL HYUNDAI DEALER TO HAVE A COMPLETE TUNE-UP, AS WELL AS CHECK A CREAKING SOUND IN THE LOWER LEFT REAR AND A "POP" SOUND WHEN DECELERATING. THE DEALER INFORMED ME THE LOWER REAR LEFT TRAILING ARM IS BAD AND NEEDS TO REPLACED ASAP FOR SAFETY REASONS AT AROUND $500. I CHECKED ONLINE AND DISCOVERED THERE WAS A RECALL ON TRAILING ARMS FOR THIS YEAR, CONTACTED HYUNDAI - WHO PROMPTLY TOLD ME IT WAS NOT COVERED AS I AM NOT IN A "ROAD SALT" STATE. THIS IS A KNOWN PROBLEM WHICH HYUNDAI ADMITS, AND I FEEL ALL OF THE TRAILING ARMS HAVE FATIGUE ISSUES FROM THESE YEARS DUE TO INFERIOR MATERIALS. I FEEL HYUNDAI SHOULD STEP UP AND COVER THE COST, NO MATTER WHAT STATE WE LIVE IN, AS IT IS A MAJOR SAFETY ISSUE THEY ARE WELL AWARE OF. WE HAVE PLENTY OF RAIN, FLOODED STREETS AND "SALT AIR" HERE IN FLORIDA! *TR

NHTSA ODI #10489574

199,000 miles · Dec 13, 2012
Seat Belts

MY SEAT BELT ALL-OF-A-SUDDEN STARTED POPPING OUT AFTER BEING SNAPPED IN PLACE. IT HAS DONE THIS A NUMBER OF TIMES SINCE LAST WEEK. YESTERDAY, IT MUST HAVE DONE IT ABOUT FIVE TIMES. I HAVE TO KEEP SNAPPING IT IN PLACE AND TUGGING ON IT TO MAKE SURE IT IS SECURE. IT IS ESPECIALLY UNNERVING WHEN IT OCCURS WHILE DRIVING. YOU MAY…

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MY SEAT BELT ALL-OF-A-SUDDEN STARTED POPPING OUT AFTER BEING SNAPPED IN PLACE. IT HAS DONE THIS A NUMBER OF TIMES SINCE LAST WEEK. YESTERDAY, IT MUST HAVE DONE IT ABOUT FIVE TIMES. I HAVE TO KEEP SNAPPING IT IN PLACE AND TUGGING ON IT TO MAKE SURE IT IS SECURE. IT IS ESPECIALLY UNNERVING WHEN IT OCCURS WHILE DRIVING. YOU MAY LEAN TO THE SIDE AND ALL-OF-A-SUDDEN IT POPS OUT. I NEVER KNOW WHEN IT WILL HAPPEN, BUT MY GREATEST CONCERN IT MAY FAIL WHEN I NEED IT MOST, LIKE IN AN ACCIDENT. *TR

NHTSA ODI #10488743

110,000 miles · Dec 12, 2012
Air BagsInjury

TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 5 MPH, THE AIR BAGS DEPLOYED WITHOUT WARNING. THE CONTACT SUSTAINED A MINOR INJURY TO HER BACK. THE VEHICLE WAS LATER TOWED TO THE DEALER FOR DIAGNOSIS WHERE THEY ADVISED HER THAT THE VEHICLE INDICATED THAT IT HAD BEEN INVOLVED IN A…

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TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 5 MPH, THE AIR BAGS DEPLOYED WITHOUT WARNING. THE CONTACT SUSTAINED A MINOR INJURY TO HER BACK. THE VEHICLE WAS LATER TOWED TO THE DEALER FOR DIAGNOSIS WHERE THEY ADVISED HER THAT THE VEHICLE INDICATED THAT IT HAD BEEN INVOLVED IN A CRASH. THEY ALSO ADVISED HER THAT THE VEHICLE COULD POSSIBLY BE DEEMED DESTROYED. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 110,000. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10488611

99,606 miles · Dec 10, 2012
Vehicle Speed Control

TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT WHILE DRIVING 35 MPH THE VEHICLE ACCELERATED INDEPENDENTLY. THE CONTACT THEN ENGAGED THE EMERGENCY BRAKE, CAUSING THE VEHICLE TO STALL. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSIS. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND THE FAILURE RECURRED. THE …

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TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT WHILE DRIVING 35 MPH THE VEHICLE ACCELERATED INDEPENDENTLY. THE CONTACT THEN ENGAGED THE EMERGENCY BRAKE, CAUSING THE VEHICLE TO STALL. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSIS. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND THE FAILURE RECURRED. THE VEHICLE WAS DIAGNOSED WITH A STUCK THROTTLE. THE THROTTLE, BRAKES AND ROTORS WERE ALL REPLACED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE AND CURRENT MILEAGE WAS 99,606.

NHTSA ODI #10487904

170,000 miles · Nov 1, 2012
Engine

TL* THE CONTACT OWNS A 2003 HYUNDIA SANTA FE. THE CONTACT STATED HAT WHILE DRIVING APPROXIMATELY 5 MPH, A LOUD NOISE EMITTED FROM THE FRONT END OF THE VEHICLE. THE ENGINE STALLED WITHOUT WARNING AND FAILED TO RESTART. THE VEHICLE WAS TOWED TO AN INDEPENDENT AUTO SHOP WHO STATED THE MALFUNCTION WAS CONTRIBUTED TO THE ENGINE MOUNT…

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TL* THE CONTACT OWNS A 2003 HYUNDIA SANTA FE. THE CONTACT STATED HAT WHILE DRIVING APPROXIMATELY 5 MPH, A LOUD NOISE EMITTED FROM THE FRONT END OF THE VEHICLE. THE ENGINE STALLED WITHOUT WARNING AND FAILED TO RESTART. THE VEHICLE WAS TOWED TO AN INDEPENDENT AUTO SHOP WHO STATED THE MALFUNCTION WAS CONTRIBUTED TO THE ENGINE MOUNT BRACKET BOLT. THE VEHICLE WAS NO REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE WAS 170,000.

NHTSA ODI #10482865

33,154 miles · Aug 21, 2012
Air Bags

I OWN A 2003 HYUNDAI SANTA FE IN WHICH THE AIR BAG WARNING LIGHT WAS ILLUMINATED STARTING IN DECEMBER 2006. AT WHICH TIME THE AIR BAG "CLOCK SPRING" WAS REPLACED UNDER WARRANTY ON 12/6/2006 AT 33,154 MILES. *TR THE SECOND OCCURRENCE WAS IN MARCH, 2011. I WAS TOLD IT WAS THE "CLOCK SPRING" AGAIN, WHICH WAS NOW NOT UNDER WARRANT…

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I OWN A 2003 HYUNDAI SANTA FE IN WHICH THE AIR BAG WARNING LIGHT WAS ILLUMINATED STARTING IN DECEMBER 2006. AT WHICH TIME THE AIR BAG "CLOCK SPRING" WAS REPLACED UNDER WARRANTY ON 12/6/2006 AT 33,154 MILES. *TR THE SECOND OCCURRENCE WAS IN MARCH, 2011. I WAS TOLD IT WAS THE "CLOCK SPRING" AGAIN, WHICH WAS NOW NOT UNDER WARRANTY, AND WOULD COST OF AROUND $285.00. THIS WAS NOT REPLACED DUE TO A SUGGESTION FROM THE DEALER'S SERVICE DEPARTMENT MECHANIC. THE INDICATOR WAS RESET AND HAS BEEN OFF FOR OVER A YEAR. THE MOST RECENT OCCURRENCE WAS IN MAY 2012 (MILEAGE APPROX. 88,500), THE AIRBAG LIGHT CAME ON AGAIN AND NOW I'M TOLD IT NEEDS A NEW AIRBAG AT A COST OF AROUND $750.00!! THE INDICATOR WAS RESET AND AIR BAG NOT REPLACED THE LIGHT STAYED OFF FOR APPROXIMATELY 3 MONTHS. A SEARCH ON THE INTERNET REVEALED HUNDREDS OF "POSTS" ON THIS VERY SAME PROBLEM (MOST OF THEM ON THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S (NHTSA) WEBSITE). HYUNDAI SANTA FE'S HAVE HAD THIS PROBLEM FOR NEARLY 10 YEARS! AND, TO MAKE MATTERS WORSE, REPLACING EITHER THE CLOCK SPRING OR THE AIRBAG APPARENTLY DOES NOT GUARANTEE THAT THE AIRBAG WILL DEPLOY, THUS CAUSING A VERY DANGEROUS SITUATION. I ALSO NOTICED THAT THERE WAS A RECALL (#103) FOR THE 2007-2008 MODELS. THIS RECALL SHOULD HAVE INCLUDED ALL SANTA FE'S NOT JUST TWO YEARS. APPARENTLY, THIS PROBLEM IS A MANUFACTURING DEFECT NOT A NORMAL WEAR & TEAR ISSUE.

NHTSA ODI #10471735

Official recalls

4

14V435000 · Suspension:front:springs:coil Springs

Jul 18, 2014

Hyundai Motor Company (Hyundai) is recalling certain model Year 2001-2006 Santa Fe vehicles manufactured from March 31, 2000, through February 15, 2006, that are registered and operated, or which were originally sold and registered, in the following 20 “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. The affected vehicles may experience front coil spring corrosion from road salt, causing the coil spring to fracture and make contact with the tire.

Consequence & remedy

Consequence: If the front coil spring fractures due to corrosion it could cause the coil spring to make contact with the tire, possibly puncturing the tire and increasing the risk of a vehicle crash.

Remedy: Hyundai will notify owners, and dealers will inspect and if necessary replace the coil spring, free of charge. The recall began on October 24, 2014. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 124.

09V123000 · Suspension:rear

Apr 16, 2009

HYUNDAI IS RECALLING 83,355 MY 2001-2003 SANTA FE 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 REAR TRAILING ARMS, WHICH COULD LEAD TO THINNING OR PERFORATION OF THE REAR TRAILING ARM STEEL. OWNERS MAY SEE OR FEEL SLIGHT TO MODERATE CHANGES IN VEHICLE OPERATION WHICH WILL INCREASE IF THE VEHICLE IS NOT REPAIRED. THESE CHANGES INCLUDE A LOWERING OF VEHICLE HEIGHT THAT CAN LEAD TO TIRE MISALIGNMENT AND STEERING PULL. OWNERS MAY ALSO NOTICE A CREAKING SOUND.

Consequence & remedy

Consequence: IF THE CORROSION IS ALLOWED TO PROGRESS, THE REAR TRAILING ARM MAY FRACTURE WHILE DRIVING, THEREBY INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL INSPECT THE REAR TRAILING ARMS FOR INTERNAL CORROSION DAMAGE. IF SPECIFIED LEVELS OF CORROSION DAMAGE ARE FOUND, THE REAR TRAILING ARMS WILL BE REPLACED. REAR TRAILING ARMS THAT DO NOT REQUIRE REPLACEMENT WILL HAVE DRAINAGE HOLES ADDED AND WILL BE TREATED WITH RUST-PROOFING MATERIAL TO ARREST THE CORROSION PROCESS. INSPECTION, TREATMENT AND REPLACEMENT PROCEDURES WILL BE CONDUCTED AT NO COST TO OWNERS. THE RECALL IS EXPECTED TO BEGIN DURING MAY 2009. OWNERS MAY CONTACT THE HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

04V131000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Mar 16, 2004

ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH 3.5 LITER V-6 ENGINES, 4-WHEEL DRIVE AND ANTILOCK BRAKING SYSTEMS (ABS), IF THE BRAKE PEDAL IS DEPRESSED AT SPEEDS BETWEEN 3 AND 12 MPH WHEN THE BRAKE PAD FRICTION SURFACES ARE WET, A VIBRATION MAY OCCUR BETWEEN THE BRAKE DISCS AND PADS CAUSING ABS SENSOR ELECTRONIC SIGNAL NOISE TO DEVELOP. AT SPEEDS BELOW 5 MPH, THE ABS SENSOR SIGNAL NOISE MAY CAUSE THE ABS ELECTRONIC CONTROL UNIT (ECU) TO ACTIVATE THE ABS, EXTENDING THE STOPPING DISTANCE.

Consequence & remedy

Consequence: IF AN EXTENDED STOPPING DISTANCE OCCURS, IT COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPROGRAM THE ABS ECU. OWNER NOTIFICATION BEGAN ON MARCH 24, 2004. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

03V520000 · Equipment:other:labels

Dec 18, 2003

CERTAIN SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."

Consequence & remedy

Consequence: THE TIRE PRESSURE LABELS DO NOT CONTAIN THE INFORMATION REQUIRED BY THE STANDARD.

Remedy: OWNERS WILL BE PROVIDED WITH A CORRECT LABEL AND INSTALLATION INSTRUCTIONS. OWNER NOTIFICATION BEGAN ON OCTOBER 29, 2003. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

EA08023 · Rear Trailing Arm Corrosion Failure

Opened Oct 28, 2008 · Closed Apr 17, 2009

Status: closed (inferred from source dates) · Suspension; Suspension:rear

IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL OF APPROXIMATELY 85,000 MODEL YEAR (MY) 2001 THROUGH 2003 HYUNDAI SANTA FE VEHICLES MANUFACTURED PRIOR TO JANUARY 27, 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 EITHER THE RIGHT OR LEFT REAR TRAILING ARMS MAY RESULT IN FRACTURE OF THE AFFECTED ARM WHILE DRIVING, WHICH COULD RESULT IN LOSS OF VEHICLE CONTROL AND A CRASH.THE REAR TRAILING ARMS 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 TRAILING ARMS.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING REAR TRAILING ARMS.ALTHOUGH NOT SUBJECT COMPONENTS OF THIS INVESTIGATION, HYUNDAI NOTED IT WOULD PERFORM A SIMILAR PROCEDURE FOR THE FRONT SUBFRAMES OF THE SUBJECT VEHICLES. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 99% OF ALL CONSUMER COMPLAINTS RELATED TO TRAILING ARM CORROSION WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 92% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 30 REAR TRAILING ARM FRACTURE INCIDENTS THROUGH ANALYSIS OF COMPLAINT AND WARRANTY INFORMATION AND CONSUMER INTERVIEWS.TWENTY-NINE (29) OF THE FRACTURE INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.

Additional source detail variants (2)

Suspension

IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL OF APPROXIMATELY 85,000 MODEL YEAR (MY) 2001 THROUGH 2003 HYUNDAI SANTA FE VEHICLES MANUFACTURED PRIOR TO JANUARY 27, 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 EITHER THE RIGHT OR LEFT REAR TRAILING ARMS MAY RESULT IN FRACTURE OF THE AFFECTED ARM WHILE DRIVING, WHICH COULD RESULT IN LOSS OF VEHICLE CONTROL AND A CRASH.THE REAR TRAILING ARMS 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 TRAILING ARMS.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING REAR TRAILING ARMS.ALTHOUGH NOT SUBJECT COMPONENTS OF THIS INVESTIGATION, HYUNDAI NOTED IT WOULD PERFORM A SIMILAR PROCEDURE FOR THE FRONT SUBFRAMES OF THE SUBJECT VEHICLES. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 99% OF ALL CONSUMER COMPLAINTS RELATED TO TRAILING ARM CORROSION WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 92% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 30 REAR TRAILING ARM FRACTURE INCIDENTS THROUGH ANALYSIS OF COMPLAINT AND WARRANTY INFORMATION AND CONSUMER INTERVIEWS.TWENTY-NINE (29) OF THE FRACTURE INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.

Suspension:rear

IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL OF APPROXIMATELY 85,000 MODEL YEAR (MY) 2001 THROUGH 2003 HYUNDAI SANTA FE VEHICLES MANUFACTURED PRIOR TO JANUARY 27, 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 EITHER THE RIGHT OR LEFT REAR TRAILING ARMS MAY RESULT IN FRACTURE OF THE AFFECTED ARM WHILE DRIVING, WHICH COULD RESULT IN LOSS OF VEHICLE CONTROL AND A CRASH.THE REAR TRAILING ARMS 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 TRAILING ARMS.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING REAR TRAILING ARMS.ALTHOUGH NOT SUBJECT COMPONENTS OF THIS INVESTIGATION, HYUNDAI NOTED IT WOULD PERFORM A SIMILAR PROCEDURE FOR THE FRONT SUBFRAMES OF THE SUBJECT VEHICLES. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 99% OF ALL CONSUMER COMPLAINTS RELATED TO TRAILING ARM CORROSION WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 92% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 30 REAR TRAILING ARM FRACTURE INCIDENTS THROUGH ANALYSIS OF COMPLAINT AND WARRANTY INFORMATION AND CONSUMER INTERVIEWS.TWENTY-NINE (29) OF THE FRACTURE INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.