IllustrationTHE HOOD FLOW UP WHILE DRIVING DOWN THE STREET GOING 55 MILE PER HOUR AND THE SAFTY LATCH BROKE AND DAMAGE $2100 TO THE CAR.
2001 Hyundai Sonata
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2001 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
140–25K
1525–50K
2350–75K
2975–100K
41100–150K
16150K+
138 reports with mileage · 67 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 69 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 47 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 29 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
27 crash reports0 fire reports17 injury reports
What owners actually said
205 reportsWHILE DRIVING ON ROUTE 202 IN RARITAN NJ, WITHOUT WARNING HOOD BLEW UP INTO THE WINDSHIELD SHATTERING THE WINDSHIELD AND DAMAGING THE HOOD. *AK
DEALERSHIP STATES BRAKES ARE NORMAL. THEY SAID ALL HYUNDAI CAR BRAKES MAKES NOISE; WORKED ON AIR BAG LIGHT - STATED IT WAS ON DUE TO SOMEONE GIVING A JUMP IN MY CAR, LIGHT CAME BACK ON 3 DAYS LATER; CHANGED A SWITCH WHICH WAS CAUSING NO ACCERALATION, CAR STILL NOT GETTING THE ACCERATION IT SHOULD. NOW I'M GETTING SOME HUMMING…
Read full complaint
DEALERSHIP STATES BRAKES ARE NORMAL. THEY SAID ALL HYUNDAI CAR BRAKES MAKES NOISE; WORKED ON AIR BAG LIGHT - STATED IT WAS ON DUE TO SOMEONE GIVING A JUMP IN MY CAR, LIGHT CAME BACK ON 3 DAYS LATER; CHANGED A SWITCH WHICH WAS CAUSING NO ACCERALATION, CAR STILL NOT GETTING THE ACCERATION IT SHOULD. NOW I'M GETTING SOME HUMMING NOISE FROM THE DASHBOARD SOMEWHERE. I HAVE HAD THIS CAR 8 MONTH. IT IS A LEMON AND JACOBS TWIN CONTINUES TO PUT A BAND-AID ON A PATIENT BLEEDING TO DEATH.*AK
WHILE DRIVING RPMS GO UP HIGH, IDLE WILL NOT DROP. VEHICLE ACCELERATED SUDDENLY AND UNEXPECTEDLY WITHOUT WARNING. CAR DRIVES OVER 40 WITHOUT FOOT ON GAS. HARD TIME BRAKING BECAUSE ENGINE IS TOO HIGH. HAS BEEN GOING ON SINCE HAD CAR. DEALER ADJUSTED CABLE AND DIDN'T WORK. ALMOST WENT THRU DEALER WALL WHEN BRINGING IT IN FOR …
Read full complaint
WHILE DRIVING RPMS GO UP HIGH, IDLE WILL NOT DROP. VEHICLE ACCELERATED SUDDENLY AND UNEXPECTEDLY WITHOUT WARNING. CAR DRIVES OVER 40 WITHOUT FOOT ON GAS. HARD TIME BRAKING BECAUSE ENGINE IS TOO HIGH. HAS BEEN GOING ON SINCE HAD CAR. DEALER ADJUSTED CABLE AND DIDN'T WORK. ALMOST WENT THRU DEALER WALL WHEN BRINGING IT IN FOR REPAIR. IS IN REPAIR SHOP AGAIN BECAUSE PROBLEM WAS NOT FIXED. CAR IS UNSAFE AND HAD NEAR COLLISIONS.*AK
WITH LESS THAN 1300 MILES ON THE VEHICLE, IT BEGAN TO BUCK AND SURGE IN TRAFFIC AT 65MPH, AND THE TACHOMETER BEGAN SWINGING WILDLY FROM 0 TO 2500RPM. AFTER GETTING OFF TO THE SIDE OF THE ROAD QUICKLY, WHERE IT STALLED AGAIN AND AGAIN, I CALLED HYUNDAI ROADSIDE ASSISTANCE FOR A TOW TO THE DEALER. THEY EXAMINED AND DROVE THE CAR, …
Read full complaint
WITH LESS THAN 1300 MILES ON THE VEHICLE, IT BEGAN TO BUCK AND SURGE IN TRAFFIC AT 65MPH, AND THE TACHOMETER BEGAN SWINGING WILDLY FROM 0 TO 2500RPM. AFTER GETTING OFF TO THE SIDE OF THE ROAD QUICKLY, WHERE IT STALLED AGAIN AND AGAIN, I CALLED HYUNDAI ROADSIDE ASSISTANCE FOR A TOW TO THE DEALER. THEY EXAMINED AND DROVE THE CAR, AND TOLD ME IT WASN'T ACTING UP FOR THEM, AND SUGGESTED I TAKE IT HOME WHILE THEY ORDERED AN EXHAUST PURGE VALVE PER A 2.4L ENGINE PROBLEM SERVICE BULLETIN FROM HYUNDAI. WHILE ON THE HIGHWAY TOWARD HOME, IT BEGAN BUCKING AND THE TACHOMETER WAS SWINGING WILDLY AGAIN, SO I GOT OFF TO THE SIDE, WHERE IT REPEATEDLY STALLED, AND AGAIN I CALLED HYUNDAI ROADSIDE ASSISTANCE FOR A TOW BACK TO THE DEALER. THEY RENTED A CAR FOR ME, AND OVER THE NEXT WEEK REPLACED THE PURGE VALVE, BUT THE CAR ALSO DIED ON THEM, SO THEY DID A MORE THOROUGH ANALYSIS, WHICH SHOWED A FAILED CRANKSHAFT POSITION SENSOR, WHICH CAUSED IGNITION SPARK FAILURE. AFTER REPLACING THAT, THEY CALLED ME TO COME GET THE CAR AND TAKE IT HOME. THIS TIME IT FAILED JUST AS I REACHED MY DRIVEWAY, AGAIN BUCKING AND STALLING WITH THE TACHOMETER SWINGING WILDLY UP AND DOWN. FOR A THIRD TIME, I CALLED ROADSIDE ASSISTANCE FOR A TOW TO THE DEALER, WHICH PROMISED A SEARCH TO DETERMINE THE CAUSE OF THE FAILURES, INVOLVEMENT OF THE DISTRICT MANAGER, AND AN ATTEMPT TO OBTAIN A DIFFERENT SENSOR MODEL IN CASE THE BATCH OF AVAILABLE SENSORS WAS "BAD". SUBSEQUENT PHONE CALLS TO THE DEALERSHIP HAVE NOT PRODUCED ANY ANSWER AS TO THE CAUSE OF THE FAILURES, DELAYS IN OBTAINING A SUITABLE REPLACEMENT PART, AND SO FAR, A TOTAL OF 18 INOPERABLE DAYS FOR MY NEW CAR. THIS FAILURE IS A SERIOUS ISSUE; A PERSON AT THE DEALERSHIP TOLD ME THAT "OTHER (HYUNDAI) VEHICLES WITH THE SAME ENGINE HAD THE SAME PROBLEM" ONE OF WHICH WAS THERE WHILE I WAS AT THE DEALER WAITING FOR MY SECOND RENTAL CAR. I REPEAT; THIS IS A SERIOUS SAFETY ISSUE; SUCH SUDDEN LOSS OF ENGINE POWER IN TRAFFIC CAN HAVE FATAL RESULTS! *AK
THE MAIN PULLEY CAME DISCONNECTED AND FELL OFF ONTO THE STREET WITH NO WARING WHATSOEVER. LUCKILY I WAS PREPARING TO TURN LEFT AND WAS STOPPED IN THE LEFT TURN LANE. THERE WAS A BAD THUNK AND SHAKE AND THE CAR SHUT DOWN. HAD I BEEN MOVING, IT COULD HAVE BEEN A VERY DIFFERENT STORY, ESPECIALLY AT HIGHWAY SPEED. IT IS A BRAND NE…
Read full complaint
THE MAIN PULLEY CAME DISCONNECTED AND FELL OFF ONTO THE STREET WITH NO WARING WHATSOEVER. LUCKILY I WAS PREPARING TO TURN LEFT AND WAS STOPPED IN THE LEFT TURN LANE. THERE WAS A BAD THUNK AND SHAKE AND THE CAR SHUT DOWN. HAD I BEEN MOVING, IT COULD HAVE BEEN A VERY DIFFERENT STORY, ESPECIALLY AT HIGHWAY SPEED. IT IS A BRAND NEW CAR, I JUST HAD THE OIL CHANGED. EVERYTHING WAS FINE, I THOUGHT. I WAS TOLD THAT THIS WAS A SERIOUS PROBLEM THAT SHOULD BE REPORTED TO YOU.
VEHICLE ACCELERATED SUDDENLY ,RESULTING IN A COLLISION, AND CAUSING MINOR INJURIES TO DRIVER. *AK CONSUMER STATES THIS ACCIDENT HAPPENED THE DAY THAT THE VEHICLE WAS GOING TO BE TAKEN TO THE DEALER FOR THIS SUDDEN ACCELERATION PROBLEM. *SLC
WHILE DRIVING ABOUT 35 MPH WAS STRUCK ANOTHER VEHICLE THAT WAS INVOLVED IN ANOTHER ACCIDENT HEAD-ON FIRST. UPON IMPACT, NONE AIR BAGS DEPLOYED. PLEASE PROVIDE MORE INFORMATION.*AK
WHILE DRIVING AT ANY SPEED DURING NORMAL OPERATION VEHICLE FAILS TO START, PROBLEM IS INTERMITTENT. DEALER HAS EXAMINED VEHICLE NUMEROUS TIMES, AND FAILED TO REMEDY PROBLEM. *AK ENGINE LIGHT ILLUMINATED AND THEN VEHICLE BEGAN HAVINB PROBLEMS WITH NO POWER, STALLING, AND MAKING NOISES, DEALER REPLACED THE PURGE CONTROL VALVE…
Read full complaint
WHILE DRIVING AT ANY SPEED DURING NORMAL OPERATION VEHICLE FAILS TO START, PROBLEM IS INTERMITTENT. DEALER HAS EXAMINED VEHICLE NUMEROUS TIMES, AND FAILED TO REMEDY PROBLEM. *AK ENGINE LIGHT ILLUMINATED AND THEN VEHICLE BEGAN HAVINB PROBLEMS WITH NO POWER, STALLING, AND MAKING NOISES, DEALER REPLACED THE PURGE CONTROL VALVE, HOWEVER PROBLEM TILL CONTINUES. BRAKES FEEL LOW TO THE FLOOR. CENTER AC VENTS AND RIGHT PASSENGER VENT BROKE, DEALER REPLACED. DEALER ADJUSTED DRIVE BELTS DUE TO BEING NOISY. *SLC
WHEN DRIVING AND WITH NO PRIOR WARNING VEHICLE WILL START TO JERK, AND THEN IT WILL ACCELERATE. *AK
Official recalls
309V124000 · 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.
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.