IllustrationDRIVING AT A LOW SPEED THE PASSENGER SIDE FRONT WHEEL SUSPENSION BROKE LEAVING WHEEL HANGING AND INOPERABLE. COULD NOT MOVE CAR OUT OF TRAFFIC LANE. UPON INSPECTION BY THE REPAIR FACILITY IT WAS DETERMINED THAT RUST TO THE SUB FRAME AND RELATED BOLTS CAUSED THE FAILURE. I WAS LUCKY THAT I WAS NOT DRIVING FASTER. *TR
1999 Hyundai Sonata Gls
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Other model years Selected year
Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
00–25K
125–50K
350–75K
1275–100K
19100–150K
6150K+
41 reports with mileage · 5 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.
- Structure. Review the 35 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
1 crash reports0 fire reports2 injury reports
What owners actually said
46 reportsON 1/7/08 WHILE DRIVING '99 HYUNDAI SONATA GLS TO WORK, PULLED RIGHT PROCEEDING DOWN ROAD. POSSIBLE LEAK FROM BRAKE CYLINDERS/ BRAKE LINES, NOTHING. RETURN TRIP, VEHICLE EXTREMELY ERRATIC STEERING. TOOK TO DEALER OF PURCHASE (BB HYUNDAI, SOUTH BRUNSWICK, NJ). DELIVERED ON 1/07/08 BY DRIVING VEHICLE. VEHICLE EXTREMELY DIFFICUL…
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ON 1/7/08 WHILE DRIVING '99 HYUNDAI SONATA GLS TO WORK, PULLED RIGHT PROCEEDING DOWN ROAD. POSSIBLE LEAK FROM BRAKE CYLINDERS/ BRAKE LINES, NOTHING. RETURN TRIP, VEHICLE EXTREMELY ERRATIC STEERING. TOOK TO DEALER OF PURCHASE (BB HYUNDAI, SOUTH BRUNSWICK, NJ). DELIVERED ON 1/07/08 BY DRIVING VEHICLE. VEHICLE EXTREMELY DIFFICULT TO STEER/ CONTROL, DRIVING SPEED 25-30 MPH. VEHICLE DELIVERED TO BB W/96062 MILES. SERVICE MGR (LC) TOOK INFORMATION REGARDING PROBLEM - DIAGNOSTIC COST OF $95 +TAX. AGREEMENT MADE TO DETERMINE FAILURE. INFORMED BY SERVICE MGR OF PROBLEM - SUB-FRAME RUSTED AWAY - COST IN EXCESS $3400. WHY NOT COVERED BY WARRANTY (10 YR OR 100,000 MILES) -"RUST' WAS COVERED. TOLD AUTO NOT ALLOWED ON ROAD. QUESTION ABSENCE OF WARRANTY SINCE SUB-FRAME REQUIRED PART OF FRONT DRIVEN AUTO. RESPONSE GIVEN - BUY A NEW CAR. REFUSED AUTHORIZATION TO REPLACE SUB-FRAME. I CONTACTED HYUNDAI USA CORPORATE CS (J) PROBLEM CONVEYED /WHY NO WARRANTY COVERAGE. REPLY-"YOU MUST LIVE BY WATER,YOU ARE IN NJ, WHY IT RUSTED OUT". TOLD ARRANGEMENTS MADE FOR FURTHER INVESTIGATION. REC'D CALL (LC) CONTACT FROM HYUNDAI, REP TO REVIEW NEXT DAY, WITH CALL FROM LC. ON 1/11/08, NO RESULTS FROM LC, TO CALL BACK. LC CALL AT 1PM, HYUNDAI, AS A GOOD WILL GESTURE, TO COVER COST OF SUB-FRAME, NOT LABOR; COSTS UNKNOWN. RECALL HYUNDAI(D) "I NEVER HEARD OF SUCH A PROBLEM!', TRANSFER TO J -ADVISED TO 'JUMP ON OFFER". RECALL LC, COST UNKNOWN. COSTS REQUIRED BY DIR/PARTS/ HYUNDAI. RECALL HYUNDAI (T)"HYUNDAI IS AWARE OF PROBLEM - RUSTING SUB-FRAMES, WORKING ON SAME". REQUEST SUPERVISOR, COMPANY POLICY DIRECTIVE, PARTS DIRECTOR WITH AUTHORITY. CONTACT BBB, 1/12/08, CALL LC, NO COST VALUE FROM MAINTANENCE SUPERVISOR COST. LC CALL@ 4 PM - COST $850, NEED OKAY TO CONTINUE. RECALL LC 5 PM - OK. INFORMED NEW SUB-FRAME WOULD NOT ARRIVE UNTIL 1/16-1/17/18. REQUESTED OLD SUB-FRAME UPON PAYMENT OF LABOR - UNABLE TO COMPLY WAS THE ANSWER. *TR
I HAVE AN 1999 HYUNDAI SONATA MY ALIGNMENT WAS OFF FROM A POT HOLE. SO I TOOK IT TO GET IT REPAIR. THEY TOLD ME THAT THE ENGINE CRADLE WAS RUSTED SO BAD THAT THE ARM CAME OUT OF IT. THEY SAID IT IS UNSAFE TO DRIVE. IT ONLY HAS 85,225 MILES ON THE CAR TO REPLACE THE CRADLE IT IS 1,800.00. I CONTACTED HYUNDAI THEY SAID MY WARRANTY…
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I HAVE AN 1999 HYUNDAI SONATA MY ALIGNMENT WAS OFF FROM A POT HOLE. SO I TOOK IT TO GET IT REPAIR. THEY TOLD ME THAT THE ENGINE CRADLE WAS RUSTED SO BAD THAT THE ARM CAME OUT OF IT. THEY SAID IT IS UNSAFE TO DRIVE. IT ONLY HAS 85,225 MILES ON THE CAR TO REPLACE THE CRADLE IT IS 1,800.00. I CONTACTED HYUNDAI THEY SAID MY WARRANTY IS UP AND THERE NOT GOING TO FIX IT. I FOUND THAT THIS A COMMON PROBLEM WITH THIS YEAR OF SONATA. ITS HAS CAUSED ONE WRECK THAT I NOW OF. THERE IS A FLAW IN THE DESIGN OF THE CRADLE. THERE IS ONLY ONE HOLE IN THE FRONT TO LET WATER IN AND OUT SO IF THE WATER GOES IN THE AIR BLOWS IT TO THE BACK AND THERE'S WHERE IT STAYS AND THAT'S THE RUST STARTS. *TR
TL*THE CONTACT OWNS A 1999 HYUNDAI SONATA GLS. WHILE DRIVING BETWEEN 5-10 MPH, THE CONTACT HEARD A CLUNKING NOISE AND THE VEHICLE SUDDENLY STOPPED. SHE COULD NOT REMEMBER IF SHE WAS ACCELERATING OR BRAKING AT THE TIME. THE ENGINE WAS STILL RUNNING. PRIOR TO THE FAILURE, THE VEHICLE WAS PULLING TO THE RIGHT AS IF AN ALIGNMENT…
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TL*THE CONTACT OWNS A 1999 HYUNDAI SONATA GLS. WHILE DRIVING BETWEEN 5-10 MPH, THE CONTACT HEARD A CLUNKING NOISE AND THE VEHICLE SUDDENLY STOPPED. SHE COULD NOT REMEMBER IF SHE WAS ACCELERATING OR BRAKING AT THE TIME. THE ENGINE WAS STILL RUNNING. PRIOR TO THE FAILURE, THE VEHICLE WAS PULLING TO THE RIGHT AS IF AN ALIGNMENT WAS NEEDED. THE VEHICLE WAS TOWED. THE REPAIR SHOP STATED THAT THE FRAME UNDER THE VEHICLE ROTTED AND CAUSED THE AXLE TO SLIP. THE SHOP REPAIRED THE PASSENGER SIDE FRONT FRAME RAIL, REASSEMBLED THE SUSPENSION, AND REINSTALLED THE AXLE. THE FAILURE MILEAGE WAS 73,800 AND CURRENT MILEAGE WAS 73,900. UPDATED 01/29/08 UPDATED 01/29/08 *TR
FRONT SUB-FRAME FAILURE DUE TO PREMATURE RUSTING. PART WAS REPLACED BY HYUNDAI AT NO COST, EVEN THOUGH THE CAR WAS 19,000 MILES PAST THE WARRANTY PERIOD. THERE WAS ANOTHER FRONT SUB-FRAME IN THE SERVICE BAY OF THE DEALERSHIP WITH VERY SIMILAR CORROSION DAMAGE IN A VERY SIMILAR LOCATION. THAT DEALER IS LOCATED AT 7115 BROOD PARK…
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FRONT SUB-FRAME FAILURE DUE TO PREMATURE RUSTING. PART WAS REPLACED BY HYUNDAI AT NO COST, EVEN THOUGH THE CAR WAS 19,000 MILES PAST THE WARRANTY PERIOD. THERE WAS ANOTHER FRONT SUB-FRAME IN THE SERVICE BAY OF THE DEALERSHIP WITH VERY SIMILAR CORROSION DAMAGE IN A VERY SIMILAR LOCATION. THAT DEALER IS LOCATED AT 7115 BROOD PARK ROAD, PARMA OHIO (GANLEY PARMA IMPORTS). *JB
APPROACHING A STOP SIGN AT AN INTERSECTION NEAR WORK, THE CAR MADE A LOUD KIND OF CRUNCHING NOISE AND CAME TO A SUDDEN STOP. I NOTICED THAT MY CAR WAS LEANING DOWN A LITTLE IN THE FRONT ON THE RIGHT SIDE. FROM INSIDE IT LOOKED LIKE I HAD A FLAT, BUT WHEN I GOT OUT OF THE CAR TO CHECK I NOTICED THAT THE RIGHT FRONT TIRE WAS LEANI…
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APPROACHING A STOP SIGN AT AN INTERSECTION NEAR WORK, THE CAR MADE A LOUD KIND OF CRUNCHING NOISE AND CAME TO A SUDDEN STOP. I NOTICED THAT MY CAR WAS LEANING DOWN A LITTLE IN THE FRONT ON THE RIGHT SIDE. FROM INSIDE IT LOOKED LIKE I HAD A FLAT, BUT WHEN I GOT OUT OF THE CAR TO CHECK I NOTICED THAT THE RIGHT FRONT TIRE WAS LEANING OUT TOWARDS THE CURB AND APPEARED TO HAVE BROKEN OFF. I TRIED TO MOVE THE CAR TO THE SIDE OF THE STREET, BUT IT WOULDN'T MOVE. I EVENTUALLY HAD MY CAR TOWED TO A LOCAL MECHANIC. I WAS INFORMED BY THE MECHANIC THAT THE LOWER CONTROL ARM HAD ROTTED AWAY FROM THE SUBFRAME. SINCE I HAD AN EXTENDED WARRANTY, BUMPER-TO-BUMPER, I CALLED THE COMPANY, UNIVERSAL UNDERWRITERS SERVICE CORPORATION. THEY LATER INFORMED MY MECHANIC THAT THEY WOULDN'T COVER ANYTHING BECAUSE THE SUBFRAME WAS NOT INCLUDED AS A COVERED PART AND ALSO BECAUSE THE DAMAGE WAS CAUSED BY CORROSION AND CORROSION VOIDS ALL COVERAGE. I THEN CONTACTED THE HYUNDAI DEALER WHO ALSO TOLD ME THE SAME THING. IT COST ME $2000 TO GET THE CAR FIXED. WHEN I WENT TO PICK UP THE CAR, THE MECHANIC SHOWED ME THE OLD SUBFRAME AND WHERE IT HAD ROTTED OUT AND I COULDN'T BELIEVE WHAT I WAS LOOKING AT. YOU COULDN'T EVEN SEE WHERE THE TWO HOLES THAT THE LOWER CONTROL ARM BOLTS INTO WERE. THERE WERE JUST TWO BIG GAPING HOLES SURROUNDED BY RUSTED METAL. HE TOLD ME THAT THE NEW SUBFRAME HAD THREE DRAIN HOLES ON BOTH SIDES OF THE SUBFRAME THAT WOULD ALLOW WATER TO DRAIN OUT. BECAUSE THE OLD SUBFRAME DIDN'T HAVE ANY DRAIN HOLES, HE FELT THAT THIS MEANT THAT HYUNDAI MADE THE CHANGES FOR SOME REASON. HE ALSO MENTIONED THAT I WAS LUCKY THAT THIS DIDN'T HAPPEN TO ME WHILE I WAS DRIVING FASTER ON A MAJOR HIGHWAY. I HAVE FOUND OTHER SONATA OWNERS ON THIS SITE WITH THE SAME PROBLEM. I AM CONCERNED FOR OTHER SONATA OWNERS WHO MAY BE DRIVING A PRODUCT WITH A CLEAR MANUFACTURE FLAW. THIS LOOKS LIKE A SAFETY CONCERN FOR THE OWNER AND FOR OTHERS ON THE ROAD. I CURRENTLY HAVE THE PART IN MY GARAGE. *TR
THE ENGINE WILL INTERMITTENTLY RACE INCREASING RPMS WITHOUT NOTICE, VERY DANGEROUS. IT HAPPENED WHILE SITTING AT A RED LIGHT. IF MY FOOT WAS NOT PUSHED DOWN ON THE BRAKE I WOULD HAVE HIT THE CAR IN FRONT, IT WILL ALSO OCCUR WHILE IN PARK WITH THE ENGINE RPMS GOING UP TO 3200 AND DOWN TO 1500 LIKE IT WAS A HUNT LASTING SEVERAL…
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THE ENGINE WILL INTERMITTENTLY RACE INCREASING RPMS WITHOUT NOTICE, VERY DANGEROUS. IT HAPPENED WHILE SITTING AT A RED LIGHT. IF MY FOOT WAS NOT PUSHED DOWN ON THE BRAKE I WOULD HAVE HIT THE CAR IN FRONT, IT WILL ALSO OCCUR WHILE IN PARK WITH THE ENGINE RPMS GOING UP TO 3200 AND DOWN TO 1500 LIKE IT WAS A HUNT LASTING SEVERAL MINUTES. IT WILL STOP ,BUT I CAN'T FIGURE OUT HOW OR WHY. IT SEEMS TO BE WORSE WHEN DRIVING AT SUSTAINED HIGHER SPEEDS ON INTERSTATE, THEN GETTING OFF THE EXIT. I DO NOTICE THAT WHEN I ACCELERATE AWAY FROM A LIGHT WHILE THE PRMS ARE HIGH THE ENGINE ALMOST CUTS OFF THEN PICKS UP IN A JERKING MOTION. IF I TURN OFF THE ENGINE WHILE THE RPMS ARE HIGH RACING I AM NOT ABLE TO RESTART FOR A WHILE. I SMELL GAS, FLOODING I ASSUME. THE REPAIR SHOP HAS NOT BEEN ABLE TO CORRECT IT SINCE IT DOES NOT HAPPEN WHILE IN THEIR HANDS. *AK
WHEN CHANGING THE OIL ON 1999 HYUNDIA SONATA GLS NOTICE DLARGE RUST HOLES ON THE SUBFRAME STRUCTURE, AND IT WAS ON THE PASSENGER SIDE. THIS SUBFRAME IS THE ENGINE CRADLE AND ALSO CONNECTS TO THE SUSPENSION. THE HOLE WAS LARGE AND COMPLETELY RUSTED THROUGH THE PART. THERE IS A CREAKING IN THE FRONT END WHEN HITTING A BUMP AS WE…
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WHEN CHANGING THE OIL ON 1999 HYUNDIA SONATA GLS NOTICE DLARGE RUST HOLES ON THE SUBFRAME STRUCTURE, AND IT WAS ON THE PASSENGER SIDE. THIS SUBFRAME IS THE ENGINE CRADLE AND ALSO CONNECTS TO THE SUSPENSION. THE HOLE WAS LARGE AND COMPLETELY RUSTED THROUGH THE PART. THERE IS A CREAKING IN THE FRONT END WHEN HITTING A BUMP AS WELL. I TOOK IT TO THE DEALER THE NEXT DAY AND THEY ADVISED ME TO REPLACE THE PART AS SOON AS POSSIBLE, PART-$1400, LABOR-$600-700. THEY SAID IT WAS OUT OF WARRANTY, AND THAT HYUNDIA WOULD NOT COVER IT. ALSO, THEY ALSO THEY NEVER HAVE SEEN THIS BEFORE. I THEN CONTACTED CONSUMER AFFAIRS AT HYUNDIA AND THEY CONTACTED THE DEALER FOR INFORMATION ON THE ISSUE, AND THEY SAID THAT THE CAR WAS WAY PAST WARRANTY AND THAT IT WOULD NOT BE COVERED. I ASKED IF THIS HAS EVER BEEN NOTED BEFORE, AND HE SAID THEY HAVE NO RECORD OF THIS FAILURE. THE TECH NICIAN AT THE DEALER SAID THAT THE CAR WAS A RISK TO DRIVE AT SPEED. *AK
HYUNDAI SONATA GLS ENGINE CRADLE RUST ONE SIDE. TIRE DEALER FOUND AND DECLARED CAR UNSAFE TO DRIVE. 1999 V6 89500 MILES - NEVER WRECKED OR OFF ROAD - DRIVER SIDE LOOKS CLEAN PASSENGER SIDE HAS A LARGE HOLE IN IT. 861968 HYUNDAI COMPLAINT #861968 *JB
FRONT PASSENGER WHEEL WOBBLE. EVENTUALLY GREW TO CAUSE VEHICLE TO SWERVE BADLY. TOOK IT TO OUR MECHANIC WHERE IT WAS DETERMINED THAT THE SUB-FRAME WAS RUSTED THROUGH. REPLACED THE SUB-FRAME WITH NEW. OLD HAD ONLY TWO HOLES TO ALLOW WATER TO DRAIN OUT, WHEREAS NEW HAD EIGHT DRAIN HOLES AND WAS TWICE THE WEIGHT OF THE ORIG…
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FRONT PASSENGER WHEEL WOBBLE. EVENTUALLY GREW TO CAUSE VEHICLE TO SWERVE BADLY. TOOK IT TO OUR MECHANIC WHERE IT WAS DETERMINED THAT THE SUB-FRAME WAS RUSTED THROUGH. REPLACED THE SUB-FRAME WITH NEW. OLD HAD ONLY TWO HOLES TO ALLOW WATER TO DRAIN OUT, WHEREAS NEW HAD EIGHT DRAIN HOLES AND WAS TWICE THE WEIGHT OF THE ORIGINAL. NEITHER THE MECHANIC NOR ALIGNMENT TECH COULD BELIEVE THAT A VEHICLE WITH NO SIGN OF RUST ANYWHERE, WOULD HAVE THIS PROBLEM. WE SPENT APPROXIMATELY 1,700.00 FOR THE REPAIR. I DO NOT HAVE THE OLD PART, BUT DID TAKE SEVERAL DIGITAL PHOTOS TO DOCUMENT THE SEVERITY OF THE PROBLEM. THE MECHANIC COULD GIVE HIS ACCOUNT AS WELL. AS A SON OF AN AUTOMOBILE MECHANIC I COULD RECOGNIZE THE SERIOUSNESS OF THE PROBLEM BEFORE IT WENT FAILURE. SOMEONE ELSE MIGHT NOT AND COULD EASILY COST SOMEONE'S LIFE. AS A MATTER OF GOOD CONSCIENCE, I WAS COMPELLED TO REPORT THE PROBLEM. *JB
Official recalls
0No recalls in this snapshot.
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
2EA08016 · Front SUB-FRAME Corrosion
Opened Aug 21, 2008 · Closed Apr 20, 2009
Status: closed (inferred from source dates) · Structure; Structure:frame And Members; Suspension; Suspension:front; Suspension:front:control Arm
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.
Additional source detail variants (5)
Structure:frame And Members
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
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:control Arm
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
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
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.
DP03001 · Improper Frontal Air Bag Performance
Opened Mar 26, 2003 · Closed Aug 1, 2003
Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal; Air Bags:frontal:sensor/control MODULE-INACTIVE
HYUNDAI HAS RECEIVED 49 REPORTS FROM CUSTOMERS STATING THE FRONTAL AIR BAGS DID NOT DEPLOY IN A CRASH FOR THE SUBJECT VEHICLES.EXAMINATION OF SUPLIMENTAL INFORMATION PROVIDED TO ODI BY THE MANUFACTURER FOR THE REPORTED CASES IT APPEARED THAT THE NECESSARY AIR BAG DEPLOYMENT THRESHOLD WAS NOT MET.THERE HAVE BEEN NO FATAL INCIDENTS OR REPORTS OF SERIOUS INJURY AS A RESULT OF BEING IN A FRONTAL CRASH AND THE AIR BAGS NOT DEPLOYING.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION REMEDY OF A SAFETY DEFECT IN THE SUBJECT VEHICLES AS DEFINED BY THE PETITIONER AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE THE NHTSA'S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY'S SAFETY MISSION, THE PETITION IS DENIED.FOR FURTHER DETAILS, REFER TO ODI?S RESPONSE TO THE PETITIONER PUBLISHED IN THE FEDERAL REGISTER VOL. 68, NO. 148, DATED AUGUST 1, 2003.
Additional source detail variants (3)
Air Bags:frontal
HYUNDAI HAS RECEIVED 49 REPORTS FROM CUSTOMERS STATING THE FRONTAL AIR BAGS DID NOT DEPLOY IN A CRASH FOR THE SUBJECT VEHICLES.EXAMINATION OF SUPLIMENTAL INFORMATION PROVIDED TO ODI BY THE MANUFACTURER FOR THE REPORTED CASES IT APPEARED THAT THE NECESSARY AIR BAG DEPLOYMENT THRESHOLD WAS NOT MET.THERE HAVE BEEN NO FATAL INCIDENTS OR REPORTS OF SERIOUS INJURY AS A RESULT OF BEING IN A FRONTAL CRASH AND THE AIR BAGS NOT DEPLOYING.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION REMEDY OF A SAFETY DEFECT IN THE SUBJECT VEHICLES AS DEFINED BY THE PETITIONER AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE THE NHTSA'S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY'S SAFETY MISSION, THE PETITION IS DENIED.FOR FURTHER DETAILS, REFER TO ODI?S RESPONSE TO THE PETITIONER PUBLISHED IN THE FEDERAL REGISTER VOL. 68, NO. 148, DATED AUGUST 1, 2003.
Air Bags:frontal:sensor/control MODULE-INACTIVE
HYUNDAI HAS RECEIVED 49 REPORTS FROM CUSTOMERS STATING THE FRONTAL AIR BAGS DID NOT DEPLOY IN A CRASH FOR THE SUBJECT VEHICLES.EXAMINATION OF SUPLIMENTAL INFORMATION PROVIDED TO ODI BY THE MANUFACTURER FOR THE REPORTED CASES IT APPEARED THAT THE NECESSARY AIR BAG DEPLOYMENT THRESHOLD WAS NOT MET.THERE HAVE BEEN NO FATAL INCIDENTS OR REPORTS OF SERIOUS INJURY AS A RESULT OF BEING IN A FRONTAL CRASH AND THE AIR BAGS NOT DEPLOYING.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION REMEDY OF A SAFETY DEFECT IN THE SUBJECT VEHICLES AS DEFINED BY THE PETITIONER AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE THE NHTSA'S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY'S SAFETY MISSION, THE PETITION IS DENIED.FOR FURTHER DETAILS, REFER TO ODI?S RESPONSE TO THE PETITIONER PUBLISHED IN THE FEDERAL REGISTER VOL. 68, NO. 148, DATED AUGUST 1, 2003.
Air Bags
HYUNDAI HAS RECEIVED 49 REPORTS FROM CUSTOMERS STATING THE FRONTAL AIR BAGS DID NOT DEPLOY IN A CRASH FOR THE SUBJECT VEHICLES.EXAMINATION OF SUPLIMENTAL INFORMATION PROVIDED TO ODI BY THE MANUFACTURER FOR THE REPORTED CASES IT APPEARED THAT THE NECESSARY AIR BAG DEPLOYMENT THRESHOLD WAS NOT MET.THERE HAVE BEEN NO FATAL INCIDENTS OR REPORTS OF SERIOUS INJURY AS A RESULT OF BEING IN A FRONTAL CRASH AND THE AIR BAGS NOT DEPLOYING.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION REMEDY OF A SAFETY DEFECT IN THE SUBJECT VEHICLES AS DEFINED BY THE PETITIONER AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE THE NHTSA'S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY'S SAFETY MISSION, THE PETITION IS DENIED.FOR FURTHER DETAILS, REFER TO ODI?S RESPONSE TO THE PETITIONER PUBLISHED IN THE FEDERAL REGISTER VOL. 68, NO. 148, DATED AUGUST 1, 2003.