1999 Hyundai Sonata GLS

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.

HYUNDAI HAS RECEIVED 49 REPORTS FROM CUSTOMERS STATING THE FRONTAL AIR BAGS DID NOT DEPLOY IN A CRASH FOR THE SUBJECT VEHICLES.EXAMINATION OF SUPLIMENTAL INFORMATION PROVIDED TO ODI BY THE MANUFACTURER FOR THE REPORTED CASES IT APPEARED THAT THE NECESSARY AIR BAG DEPLOYMENT THRESHOLD WAS NOT MET.THERE HAVE BEEN NO FATAL INCIDENTS OR REPORTS OF SERIOUS INJURY AS A RESULT OF BEING IN A FRONTAL CRASH AND THE AIR BAGS NOT DEPLOYING.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION REMEDY OF A SAFETY DEFECT IN THE SUBJECT VEHICLES AS DEFINED BY THE PETITIONER AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE THE NHTSA'S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY'S SAFETY MISSION, THE PETITION IS DENIED.FOR FURTHER DETAILS, REFER TO ODI?S RESPONSE TO THE PETITIONER PUBLISHED IN THE FEDERAL REGISTER VOL. 68, NO. 148, DATED AUGUST 1, 2003.

TL* THE CONTACT OWNS A 1999 HYUNDAI SONATA GLS. WHILE MAKING A LEFT TURN AT A TRAFFIC LIGHT, THE FRONT PASSENGER SIDE SUSPENSION SEPARATED FROM THE VEHICLE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE VEHICLE WAS INCLUDED IN NHTSA ACTION NUMBER: EA08016 (STRUCTURE, SUSPENSION). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 150,000.

NHTSA ID

10735598

Incident

Feb 17, 2015

Mileage

150,000 mi

I OWN A 1999 HYUNDAI SONATA AND WAS INFORMED BY MY MECHANIC THAT THE FRONT SUB FRAME ON THE PASSENGER SIDE IS RUSTING THROUGH, PRESENTING A SEVERE SAFETY RISK TO THE DRIVER AND PASSENGERS. THERE IS CURRENTLY A MANUFACTURER'S RECALL SHOWING FOR THE 2001-2004 MODEL FROM YOUR INVESTIGATION. SHOULDN'T THE 1999 BE INCLUDED DUE TO IT HAVING MANY COMPLAINTS DUE TO THIS CORROSION ISSUE. THE VEHICLE WAS PURCHASED IN MARYLAND AND OWNED IN VIRGINIA FOR A PERIOD OF TIME. IT ALSO HAS BEEN IN OUT OF VIRGINIA FOR THE LAST TEN YEARS WHERE SALT IS APPLIED TO ROADWAYS LIKELY CONTRIBUTING THIS PROBLEM. THE VEHICLE IS CURRENTLY REGISTERED IN NORTH CAROLINA AND THE LOCAL HYUNDAI DEALERSHIP REFUSES TO MAKE THE REPAIR. *TR

NHTSA ID

10505528

Incident

Apr 3, 2013

Mileage

189,200 mi

1999 HYUNDAI SONAT GLS AIRBAG WARNING LIGHT CONTINUES TO COME ON AFTER BEING WORKED ON BY HYUNDAI DEALER 10-15 TIMES. WAS WORKED ON WITHOUT ISSUE WHILE UNDER WARRANTY WITH NO SUCCESS. ONCE EXTENDED WARRENTY EXPIRED, THE DEALER THEN KNEW THAT THE CAR NEEDED A NEW WIRE HARNESS FOR ABOUT $1000. THE SERVICE MANAGER THEN SUGGESTED THAT I HARD -WIRE THE WIRE HARNESS TO GET AROUND THE CONNECTOR ISSUE. IS THERE A RECOURSE TO AN AIRBAG PROBLKEM THAT HAS BEEN WORKED ON AT LEAST A DOZEN TIMES? *TR

NHTSA ID

10393016

Incident

Apr 1, 2010

VEHICLE HAD DEVELOPED A FRONT END ALIGNMENT PROBLEM, AND I SCHEDULED AN ALIGNMENT. THE MORNING BEFORE THE SCHEDULED ALIGNMENT, I WAS PULLING OUT OF MY DRIVEWAY TO GO TO WORK WHEN THE RIGHT INNER CV JOINT DISINTEGRATED. INVESTIGATION REVEALED SEVERE SUBFRAME CORROSION RESULTING IN THE CONTROL ARM MOUNT SEPARATING FROM THE SUBFRAME, CAUSING THE CV JOINT TO FAIL AND THE VEHICLE TO BECOME INOPERABLE. NHTSA AND HYUNDAI ISSUED A RECALL IN 2009, CAMPAIGN ID NUMBER: 09V124000. HOWEVER, THE STATE I RESIDE IN (NEBRASKA) IS NOT LISTED AS A "SALT BELT" STATE AND IS NOT COVERED BY THE RECALL. NEBRASKA DOES INDEED USE SALT ON THE ROADS, AND THE DESCRIPTION OF THE FAULT AND POTENTIAL RESULTS MATCHES EXACTLY WITH THE RUST AND CORROSION ON MY VEHICLE'S SUBFRAME AND THE RESULTS. I BELIEVE IT LIKELY THAT THERE ARE OTHER MOTORISTS IN THE STATE OF NEBRASKA WHO ARE DRIVING THESE VEHICLES WITH THIS HIDDEN AND POTENTIALLY VERY DANGEROUS FAULT. THE HYUNDAI DEALER HAS BEEN UNABLE TO HELP ME SO FAR WITH A FAULT RESOLUTION PER THE RECALL. *TR

NHTSA ID

10361117

Incident

Oct 4, 2010

Mileage

135,150 mi

I HAVE A DEFECTIVE SUBFRAME ON A 1999 SONATA PURCHASED NEW IN IOWA AND DRIVEN THERE FOR 4 YEARS. IT HAS COMPLETELY RUSTED OUT ON THE PASSENGER FRONT SIDE CAUSING STEERING CONTROL ARMS AND DRIVE AXLE TO BREAK LOOSE FROM VEHICLE AND MAKING VEHICLE INOPERABLE. THIS SHOULD BE COVERED UNDER HYUNDAI RECALL CAMPAIGN 089. NHTSA CAMPAIGN ID NO. 09V124000. I AM GETTING NO RESPONSE AS TO IF THEY WILL COVER THIS DAMAGE AND REPLACE SUBFRAME FROM THE LOCAL DEALER TAMIAMI HYUNDAI IN NAPLES, FL AND HAVE ALSO CONTACTED THE HYUNDAI CUSTOMER ASSISTANCE CENTER 3 TIMES TO NO AVAIL. I WAS TOLD BY A MECHANIC THAT IF THIS WOULD HAVE HAPPENED AT HIGHWAY SPEEDS I WOULD HAVE PROBABLY LOST CONTROL OF VEHICLE AND IT WOULD HAVE ROLLED. NEVER SINCE I OWNED THE VEHICLE WAS TOLD OF THIS RECALL AND THEY CURRENTLY STATE THE VIN OF THE VEHICLE IS NOT BEING SHOWN IN THE RECALL LIST, BUT IT WAS PURCHASED NEW IN IOWA SO IT SHOULD BE INCLUDED. *TR

NHTSA ID

10359329

Incident

Sep 20, 2010

Mileage

129,500 mi

I OWN A 1999 HYUNDAI SONATA AND WAS INFORMED BY MY MECHANIC THAT THE FRONT SUB FRAME ON THE PASSENGER SIDE IS RUSTED THROUGH, PRESENTING A SEVERE SAFETY RISK TO THE DRIVER AND PASSENGERS. THERE IS CURRENTLY A MANUFACTURER'S RECALL DUE TO THIS CORROSION ISSUE. THE VEHICLE WAS PURCHASED AND DRIVEN IN MINNESOTA FOR THE LAST TEN YEARS WHERE SALT IS APPLIED TO ROADWAYS LIKELY CONTRIBUTING THIS PROBLEM. THE VEHICLE IS CURRENTLY REGISTERED IN GEORGIA AND THE LOCAL HYUNDAI DEALERSHIP REFUSES TO MAKE THE REPAIR. *TR

NHTSA ID

10302041

Incident

Jan 23, 2010

Mileage

100,000 mi

ON 1 OCT 2009 MY SON WAS DRIVING HIS 1999 HYUNDAI SONATA GLS FROM HIS HIGH SCHOOL TO PICK UP HIS SISTER AT THE DAYCARE JUST DOWN THE ROAD. UPON PULLING INTO THE DAYCARE PARKING LOT HE HEARD A LOUD SOUND AND THE FRONT PASSENGER SIDE OF THE VEHICLE DROPPED SIGNIFICANTLY. HE IMMEDIATELY STOPPED THE VEHICLE AND GOT OUT TO SEE IF HE HAD HIT SOMETHING OR TO SEE EXACTLY WHAT HAD HAPPENED. UPON INSPECTION THE FRONT PASSENGER SIDE A-FRAME HAD COMPLETELY RUSTED OUT OF THE SUB FRAME OF THE VEHICLE CAUSING IT TO BREAK COMPLETELY OFF. THANKFULLY HE WAS TRAVELING AT A LOW RATE OF SPEED OR IT COULD HAVE CAUSED A MAJOR ACCIDENT OR EVEN FURTHER DAMAGE TO THE VEHICLE. UPON RESEARCH IT WAS DISCOVERED THAT THERE IS A NHTSA CAMPAIGN ID NUMBER: 09V124000 THAT ADDRESSES THIS SAME ISSUE, HOWEVER IT LOOKS LIKE IT DOESN'T COVER A RECALL OF THE 1999 MODEL AND WHEN I CONTACTED THE DEALERSHIP THEY STATED THERE WAS NO RECALL FOR THIS VEHICLE. YOU CAN CONTACT ME AT [email protected] OR AT 813-451-6532. I?M HIGHLY CONCERNED FOR THE SAFETY FOR ANYONE THAT DRIVES THIS VEHICLE AND I FEEL THAT SINCE THIS SEEMS TO BE A SYSTEMIC ISSUE THAT IT SHOULD BE COVERED UNDER THE FACTORY RECALL CAMPAIGN AS THIS VEHICLE WAS ORIGINALLY TITLED IN MISSOURI. *TR

NHTSA ID

10286010

Incident

Oct 1, 2009

Mileage

120,000 mi

DRIVING DOWN THE ROAD THE CAR BEGAN TO PULL TO THE RIGHT. COULD BARELY DRIVE TO THE SHOP. THEY FOUND OUT THE FRAME WAS RUSTED SO BAD IT WAS NOT DRIVABLE. THE TIRE WHICH WERE NEW JUST 3 MONTHS AGO WERE TOTALLY BALD. THE CAR, A 1999 HYUNDAI SONATA, IS NOW NOT DRIVABLE. *TR

NHTSA ID

10275119

Incident

Jun 27, 2009

Mileage

176,395 mi

This bulletin provides important checkpoint guidelines when performing engine oil and filter change services.

Hyundai applies a Paint Protection Film (PPF) on new vehicles before delivery to dealerships. It provides a barrier between the paint and contaminants, such as rail dust, acid rain, and industrial fallout. In rare cases, the paint can become clouded under the PPF. These spots are the result of moisture trapped between the PPF and the paint.

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation.

Follow the guidelines outlined in this bulletin to inspect and clean or replace certain components of the engine intake system accordingly during engine short block or sub-assembly replacement.

Effective June 2, 2008, Federal Motor Vehicle Safety Standard 110 (FMVSS 110) established a threshold for correcting load carrying capacity information indicated on tire placards when vehicle weight has been increased before retail sale. This limit is the lesser of 1.5% of GVWR or 100 pounds. If the total added weight exceeds the lesser of the limit, a label must be added to the driver-side B-pillar within 25mm (1 inch) of the original tire placard.

This bulletin provides the service procedure for engine connecting rod bearing clearance testing. Perform the procedure outlined in this bulletin to fulfill the Bearing Clearance Test inspection requirements to determine next required steps.