IllustrationTL*THE CONTACT OWNS A 2000 HYUNDAI SONATA. WHILE APPROACHING A STOP AT 10 MPH, THE DRIVER SEAT SLID. THE DEALER STATED THAT THE SEAT ROLLERS FAILED. THE SEAT HAS NOT BEEN REPAIRED. THE VIN WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 86,000.
2000 Hyundai Sonata
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2000 Hyundai Sonata do not stand out strongly from the model-year median of 161.
About this comparison →How this year compares
Owner complaints by model year
Compare all Sonata years →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
100–25K
725–50K
3250–75K
3075–100K
71100–150K
26150K+
176 reports with mileage · 100 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 109 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 64 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
20 crash reports9 fire reports10 injury reports
Seats complaints
2 reportsVEHICLE HAS BEEN TO DEALER 5 TIMES FOR STALLING, RECALL ON STALLING PERFORMED NOVEMBER 2000. DEALER CANNOT REMEDY PROBLEM. *AK THE VEHICLE STALLS INTERMNITTENTLY AT STOP SIGN, RED LIGHTS, LOW SPEED DRIVING, WHILE BACKING OUT AND ON HIGHWAYS, DEALER HAS ATTEMPTED TO FIX THIS PROBLEM SEVERAL TIMES HOWEVER HAS NOT BEEN SUCCESSF…
Read full complaint
VEHICLE HAS BEEN TO DEALER 5 TIMES FOR STALLING, RECALL ON STALLING PERFORMED NOVEMBER 2000. DEALER CANNOT REMEDY PROBLEM. *AK THE VEHICLE STALLS INTERMNITTENTLY AT STOP SIGN, RED LIGHTS, LOW SPEED DRIVING, WHILE BACKING OUT AND ON HIGHWAYS, DEALER HAS ATTEMPTED TO FIX THIS PROBLEM SEVERAL TIMES HOWEVER HAS NOT BEEN SUCCESSFUL, EVEN WITH RECALL 00V259001 REPAIR THE VEHICLE IS NOT FIXED, DEALER HAS ALSO REPLACED THE AIR FLOW SENSOR CONNECTION, PURGE VALVE (ON 6 OCCASIONS), TPS SENSOR AND EXTENSION, AND OTHER SENSOR ASSEMBLIES. LUMBAR SUPPORT WOULD NOT HOLD, DEALER REPLACED. TRUNK WOULD NOT STAY OPEN ON INCLINE. *SLC
Official recalls
409V124000 · Suspension
Apr 16, 2009
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 & remedy
Consequence: 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.
Remedy: 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.
02V105000 · Air Bags:side/window
Apr 9, 2002
ON CERTAIN PASSENGER VEHICLES, AN INTERMITTENT CONDITION THAT LEADS TO THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG WARNING LIGHT ILLUMINATION COULD RESULT FROM MOTION OF THE SIDE IMPACT AIR BAG WIRING HARNESS AND SIDE IMPACT AIR BAG WIRING HARNESS CONNECTOR WHICH MOUNT TO THE ADJUSTABLE SEAT CUSHION ASSEMBLY. THIS CONDITION ONLY RELATES TO THE SIDE IMPACT AIR BAGS AND COULD PREVENT AIR BAG DEPLOYMENT DURING A CRASH WHERE SUCH DEPLOYMENT SHOULD OCCUR.
Consequence & remedy
Consequence: NON-DEPLOYMENT OF THE SRS SIDE IMPACT AIR BAG COULD INCREASE THE RISK OF INJURY DURING A SIDE IMPACT CRASH.
Remedy: DEALERS WILL MORE SECURELY FASTEN THE SIDE IMPACT AIR BAG WIRING HARNESSES AND CONNECTORS TO THE VEHICLE'S FRONT SEAT CUSHION FRAMES. OWNER NOTIFICATION BEGAN MAY 28, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
01V347000 · Air Bags
Nov 6, 2001
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG WARNING LIGHT COULD ILLUMINATE DUE TO MOTION OF THE SIDE IMPACT AIR BAG WIRING HARNESS AND SIDE IMPACT AIR BAG WIRING HARNESS CONNECTOR THAT MOUNT TO THE ADJUSTABLE SEAT CUSHION ASSEMBLY. THIS CONDITION ONLY RELATES TO THE DRIVER AND/OR PASSENGER SEAT-MOUNTED SIDE IMPACT AIR BAG(S).
Consequence & remedy
Consequence: THIS CONDITION COULD PREVENT SEAT MOUNTED SIDE IMPACT AIR BAG DEPLOYMENT DURING AN ACCIDENT WHERE SUCH DEPLOYMENT SHOULD OCCUR. NON-DEPLOYMENT OF THE SRS SIDE IMPACT AIR BAGS COULD INCREASE THE RISK OF INJURY DURING AN ACCIDENT WHERE SIDE IMPACT AIR BAG DEPLOYMENT IS INTENDED.
Remedy: DEALERS WILL MORE SECURELY FASTEN THE FRONT SEAT SIDE IMPACT AIR BAG WIRING HARNESS AND CONNECTORS TO THE VEHICLE'S FRONT SEAT CUSHION FRAMES. OWNER NOTIFICATION WILL OCCUR IN SIX MAILINGS ON MAY 27, JUNE 3, JUNE 10, JUNE 17, JUNE 24, AND JULY 1, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
00V259001 · Electrical System:wiring
Sep 11, 2000
VEHICLE DESCRIPTION: SOME SONATA VEHICLES EQUIPPED WITH 2.5 LITER V-6 ENGINES AND ALL ELANTRA MODEL VEHICLES MAY HAVE EXPERIENCED INTERMITTENT LOW-SPEED ENGINE STALLING, WHICH COULD OCCUR IF THE MAF (MASS AIR FLOW) SENSOR ELECTRICAL SIGNAL IS INTERRUPTED AS A RESULT OF ENGINE VIBRATION TRANSMITTED TO THE MAF SENSOR CONNECTOR WIRING HARNESS.
Consequence & remedy
Consequence: THIS CONDITION CAN CAUSE THE ENGINE TO STALL, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL RE-ROUTE THE MAF SENSOR CONNECTOR WIRING HARNESS.
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.
PE08029 · Front SUB-FRAME Corrosion
Opened Apr 22, 2008 · Closed Aug 21, 2008
Status: closed (inferred from source dates) · Structure:frame And Members; Suspension; Suspension:front; Suspension:front:control Arm
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.
Additional source detail variants (4)
Structure:frame And Members
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
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
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
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.