Illustration2004 Hyundai Sonata GLS front sub frame (K Frame) has rusted out but I guess for certain VIN numbers there was a recall. Mine has the same issue and has caused suspension issues with the control arms and axles, subframe has snapped due to rusting in Michigan.
2004 Hyundai Sonata
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2004 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
190–25K
1825–50K
2850–75K
2875–100K
45100–150K
17150K+
155 reports with mileage · 47 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Suspension. Review the 56 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 47 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 46 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
22 crash reports2 fire reports23 injury reports
Steering complaints
13 reportsNHTSA Campaign 09V124000 (Hyundai Recall #089) - excessive corrosion, thinning of the metal and perforation of the front sub-frame steel, due to road salt, resulting in separation of the forward mounting of the lower control arm increasing the risk of a crash. The recall was issued in 2009 for 1999-2004 Hyundai Sonatas. The pr…
Read full complaint
NHTSA Campaign 09V124000 (Hyundai Recall #089) - excessive corrosion, thinning of the metal and perforation of the front sub-frame steel, due to road salt, resulting in separation of the forward mounting of the lower control arm increasing the risk of a crash. The recall was issued in 2009 for 1999-2004 Hyundai Sonatas. The present owner purchased the vehicle in 2014 with no knowledge of previous recall. The excessive corrosion and perforation of the sub-frame was brought to the owner's attention in December 2022 during a routine oil change by a Meineke shop and reported as unsafe to drive. The vehicle was towed to Route 1 Hyundai in Monmouth Junction, New Jersey, for inspection and repair estimate on December 30, 2022 and an online complaint filed with Hyundai Motor America for the recall (Case #[XXX]). Following numerous email communications to Hyundai Consumer Affairs, it was confirmed by a National Consumer Affairs representative that the vehicle was covered in Hyundai Recall #089. Route 1 Hyundai took photos of the front sub-frame and H-frame, completed a report and submitted it to Hyundai Motor America. Hyundai Motor America responded that they are declining assistance due to the failure being out of warranty caused by the time in service and mileage of the vehicle. The vehicle has 80,000 miles on the odometer. I am of the understanding that safety recalls are never out of date. Please verify if the response made by Hyundai Motor America is justified. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
I HAVE A 04 HYUNDAI SONATA WHICH WAS RECALLED FOR THE SUBFRAME ROT AND THE DEALERSHIP SAYS IT DOESNT COME UP WITH MY VIN BUT IV HAD TO REPLACE 2 TIRED AND A TIE ROD AND THE SUB FRAME IS GETTING WORSE CAUSING MORE DAMAGE MY CAR PULLS BANGS AND ONE DAY MY WHOLE SUSPENSION WILL DETACH AND HOW IS IT NOT UNDER THE RECALL I HAVE A HOU…
Read full complaint
I HAVE A 04 HYUNDAI SONATA WHICH WAS RECALLED FOR THE SUBFRAME ROT AND THE DEALERSHIP SAYS IT DOESNT COME UP WITH MY VIN BUT IV HAD TO REPLACE 2 TIRED AND A TIE ROD AND THE SUB FRAME IS GETTING WORSE CAUSING MORE DAMAGE MY CAR PULLS BANGS AND ONE DAY MY WHOLE SUSPENSION WILL DETACH AND HOW IS IT NOT UNDER THE RECALL I HAVE A HOUSE AND TWO CHILDREN AND CAN NOT AFFORD A NEW CAR SO PLEASE HELP ME UNDERSTAND
TAKATA RECALL MY STEERING GET TIGHT WHILE I'M DRIVING WHICH MAKES IT HARD TO TURN WHILE ON THE HIGHWAYS
THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE DUE TO STEERING ISSUES AND FRONT END NOISE AN INDEPENDENT MECHANIC DIAGNOSED THAT THERE WAS EXTENSIVE RUST AND CORROSION CONCERNING THE FRONT CRADLE FRAME NEAR THE FRONT PASSENGER SIDE TIRE AND NEAR THE CONCENTRIX BRAKE ADJUSTMENT FOR …
Read full complaint
THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE DUE TO STEERING ISSUES AND FRONT END NOISE AN INDEPENDENT MECHANIC DIAGNOSED THAT THERE WAS EXTENSIVE RUST AND CORROSION CONCERNING THE FRONT CRADLE FRAME NEAR THE FRONT PASSENGER SIDE TIRE AND NEAR THE CONCENTRIX BRAKE ADJUSTMENT FOR BOTH REAR TIRES PERTAINING TO THE SUBFRAME. THE INDEPENDENT MECHANIC ADVISED THE CONTACT TO CONTACT THE LOCAL DEALER FOR THE MANUFACTURER FOR A RECOMMENDATION.DEALER RECOMMENDS THE ENTIRE CRADLE BE REPLACED AS IT WILL NOT LAST MUCH LONGER AND CAN BE DANGEROUS TO DRIVE AS IT IS ALMOST RUSTED THROUGH AND THE REAR BRAKES CANNOT BE ADJUSTED DUE TO RUST. THERE IS A RECALL 09V124000 FOR THIS FOR CARS FROM THE RUSTBELT STATES BUT I AM IN TN AND IT IS NOT COVERED. I AM IN THE MOUNTAINS OF NORTH EAST TN AND IT SHOULD BE COVERED AS WE ALSO GET SNOW AND THEY SALT THE ROADS. THIS CAR IS DANGEROUS TO DRIVE IN ITS PRESENT CONDITION AND HYUNDAI NEEDS TO HAVE THIS FIXED AS OBVIOUSLY FROM THE COMPLAINTS THERE IS LOTS OF THIS. MFG IN SEPT OF 2003 SO IT IS WITHIN THE TIME FRAME
THE 2004 HYUNDAI SONATA HAS A RECALL FOR THE FRONT SUB FRAME RUSTING TO THE POINT WHERE THE FRONT SUSPENSION MOUNT RUST TO THE EXTENT THAT THE LOWER CONTROL ARM SEPARATES FROM IT'S MOUNTING BRACKET WHICH CAN CAUSE LOSS OF CONTROL AND POSSIBLE ACCIDENT. THERE IS A RECALL FOR THIS FOR CARS THAT WERE SOLD OR REGISTERED IN THE SALT …
Read full complaint
THE 2004 HYUNDAI SONATA HAS A RECALL FOR THE FRONT SUB FRAME RUSTING TO THE POINT WHERE THE FRONT SUSPENSION MOUNT RUST TO THE EXTENT THAT THE LOWER CONTROL ARM SEPARATES FROM IT'S MOUNTING BRACKET WHICH CAN CAUSE LOSS OF CONTROL AND POSSIBLE ACCIDENT. THERE IS A RECALL FOR THIS FOR CARS THAT WERE SOLD OR REGISTERED IN THE SALT BELT STATES. EVERY STATE IN MY AREA ARE LISTED EXCEPT MY STATE OF VIRGINIA. MY CARS SUB FRAME COMPLETELY RUSTED THROUGH TO WHERE THE LOWER CONTROL ARM SEPARATED FROM IT'S BRACKETS WHILE MOVING ENTERING AN EXIT ONTO A MAJOR HIGHWAY I95 CAUSING SEVERE DAMAGE WHICH ISN'T COVERED. THE RECALL IS 09V124000. I BELIEVE VIRGINIA SHOULD BE ADDED TO THIS RECALL DUE TO IT BEING IN THE SAME AREA AS THE OTHER STATES WITH THE SAME WEATHER PATTERN.
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING UNKNOWN SPEEDS, THE STEERING WAS UNSTABLE AND THE VEHICLE SHOOK. THE CHECK ENGINE INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE CRADLE HAD A LARGE RUST SPOT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE…
Read full complaint
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING UNKNOWN SPEEDS, THE STEERING WAS UNSTABLE AND THE VEHICLE SHOOK. THE CHECK ENGINE INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE CRADLE HAD A LARGE RUST SPOT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 188,000.
WHEN I DRIVE IN THE RAIN AND GO THROUGH STANDING WATER THE STEERING COLUMN FREEZES MAKING IT VIRTUALLY IMPOSSIBLE TO MOVE.
SEVERE CORROSION ON FRONT SUBFRAME. IT IS A RECALL BUT NO FEEDBACK FROM HYUNDAI. SALT BELT CORROSION (LAWSUIT) AGAIN NO FEEDBACK. EXTREMELY DANGEROUS , COULD RESULT IN INJURY
FRONT SUB FRAME RUSTED. CRACK IN THE SUB FRAME NEAR THE RIGHT FRONT WHEEL. CAR HAS 70,000 MILES ON IT. DANGER OF SUBFRAME BREAKING AND CONTROL ARM DISCONNECT.
Official recalls
109V124000 · 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.
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
1EA08016 · 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.