1999 Hyundai Sonata

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.

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.

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.

I WAS DRIVING HOME FROM WORK ON JAN 30TH, 2015 AND THE CAR STARTED PULLING TO THE RIGHT. THE NEXT DAY, SAT THE 31ST, I JACKED UP THE RIGHT FRONT OF THE CAR TO SEE WHY THE CAR STEERED TO THE RIGHT. I FOUND THE LOWER WHEEL ASSEMBLY ATTACHMENT TO THE FRAME HAD COME LOOSE. THAT WAS BECAUSE THE FRAME HAD THREE OF FOUR SIDES RUSTED THRU. THE CONDITION COULD HAVE CAUSED A MORE SEVERE ACCIDENT IF THE ATTACHMENT TO THE FRAME HAD PULLED COMPLETELY APART. I WILL CHECK WITH HYUNDAI TO SEE WHAT THEY CAN DO ABOUT IT. THANKS FOR LISTENING. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10680767

Incident

Jan 30, 2015

Mileage

114,000 mi

AFTER REMOVING THE DRIVERS FRONT WHEEL I NOTICED THE CONTROL ARM ATTACHMENT POINT SEVERELY RUSTED, & THE SUB FRAME CRACKED READY TO BREAK. I KNOW ABOUT THE RECALL. UNFORTUNATELY NEBRASKA ALONG WITH OTHER STATES WERE NOT INCLUDED. THIS CAR WAS WELL MAINTAINED BY THE ORIGINAL OWNER, & DRIVEN VERY LITTLE IN SALT/ SNOW CONDITIONS. SHE PURCHASED @ APPROX. 80 YEARS OF AGE. NHTSA SHOULD TAKE A LOOK AT THIS AGAIN. WATER BEING TRAPPED IN THE SUB FRAMES IS THE REAL PROBLEM, SALT MAY HAVE ONLY MADE THE FAILURE HAPPENED A BIT SOONER. I HAVE TALKED WITH HYUNDAI CUSTOMER ASSISTANCE, & WAS TOLD THE CAR WOULD NOT BE COVERED BY THE RECALL. I LIVE 8 MILES AWAY FROM IOWA, WHICH IS COVERED BY THE RECALL. OMAHA DOES USE SALT ON THE STREETS. 14 -15 YEARS FOR A SUB FRAME TO ROT AWAY SEEMS QUITE SHORT. THE PROBLEM IS A DESIGN DEFECT NOT ALLOWING THE WATER TO GET OUT. NO STATES SHOULD HAVE BEEN LEFT OUT! WHO DOESN'T WASH THEIR CAR REGULARLY? HOW MANY 1999-2004 MODELS OF THIS CAR ARE STILL ON THE ROAD? FORTUNATELY FOR OUR FAMILY WE NOTICED THE STEERING WHEEL SIGNIFICANTLY OUT OF POSITION, & BOTH FRONT WHEELS LEANING IN AT THE TOP. SEPARATION OF THE CONTROL ARM FROM THE FRAME WOULD NOT PRETTY AT A HIGHER RATE OF SPEED. PEOPLE THAT HAVE LOOKED AT THE PICTURES I TOOK OF BOTH SIDES ON THIS CAR SEEM TO AGREE, WE WERE PROBABLY ONLY A FEW MORE CHUCK HOLES AWAY! WILL HYUNDAI NOTIFY CURRENT OWNERS OF ANY OF THESE CARS REGARDLESS OF WHICH STATE & REMEDY CORRECTLY?? WILL HYUNDAI, OR GOVERNMENT PUT OUT TSB'S OR PSA'S ALERTING ANY CURRENT OWNERS OF THE POTENTIALLY CATASTROPHIC CONDITION WHICH MAY COST SOMEONE THEIR LIFE? *TR

NHTSA ID

10575446

Incident

Mar 19, 2014

Mileage

75,800 mi

L WAS STOPPED ON TRAFFIC ON HIGH WAY ,AND SOME ONE, HIT ME ON THE BACK ,THE GUY WAS SO FAST PROBLEM MORE THAN 75 MPH ,THAN MY CAR FLOAT 20 FOOT ,AND HIT THE CAR ON MY FRONT AND MY AIR BAGS DID NOT DEPLOY OR OPEN , SO THE QUESTION IS HYUNDAI SONATA 1999 USUALLY HAVE THIS PROBLEM , ???? *TR

NHTSA ID

10558957

Incident

Jan 4, 2014

Mileage

123,000 mi

THE SUB FRAME/K FRAME ON MY 99 HYUNDAI SONATA RUSTED OUT CAUSING MY DRIVER SIDE REAR TIRE AND PASSENGER SIDE REAR TIRE TO FACE OUTWARDS ALMOST COMING OFF AND DAMAGING MY LEFT CONTROL ARM. I HEARD A LOUD POP AND COULDN'T FIGURE OUT WHAT IT WAS THEN REALIZED THE STEERING WHEEL WAS COCKED AT 180. I HAD TO DRIVE IT HOME WHICH WAS LUCKILY ONLY 2 MINUTES DOWN THE ROAD, I HAD TO DRIVE 10MPH SMELLING BURNING RUBBER. *TR

NHTSA ID

10552133

Incident

Nov 1, 2013

Mileage

213,627 mi

I WAS PULLING IN A SHOPPING CENTER TURNING THE STEERING WHEEL TO THE RIGHT, I HEARD A LOUD BANG AND GOT OUT OF CAR, THE DRIVERS SIDE WHEEL WAS CAVED IN, HAD CAR TOWED TO MECHANIC, HE SAID THE SUBFRAME WAS COMPLETELY RUSTED AND BROKE AWAY FROM THE CAR, AND I WAS LUCKY THAT I WASN'T GOING AT A HIGHER SPEED. *TR

NHTSA ID

10549738

Incident

Aug 5, 2013

Mileage

165,000 mi

TL* THE CONTACT OWNS A 1999 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, HE HEARD NOISES AND NOTICED THAT THE TIRE WAS MISALIGNED CAUSING THE STEERING WHEEL PULLING ABNORMALLY. THE VEHICLE WAS TAKEN TO THE MECHANIC AND AFTER INSPECTION, THEY FOUND THAT THE FRONT SUB-FRAME WAS RUSTED AND CORRODED. THERE WERE ALSO HOLES NEXT TO THE BOLTS THAT HELD THE SUB FRAME IN PLACE. THE DEALER WAS NOTIFIED WHO ADVISED THE CONTAC THAT THERE WAS A RECALL FOR THE FAILURE BUT HIS VIN WAS NOT INCLUDED (NHTSA CAMPAIGN ID NUMBER: 09V124000: SUSPENSION). THE MANUFACTURER WAS NOTIFIED WHO CONFIRMED THAT THE CONTACT'S VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 157,000.

NHTSA ID

10487546

Incident

Nov 3, 2012

Mileage

157,000 mi

TL* THE CONTACT OWNS A 1999 HYUNDAI SONATA. THE CONTACT STATED THAT THE VEHICLE WAS BEING EXAMINED BY AN INDEPENDENT REPAIR SHOP AND SHE WAS INFORMED THAT THE FRONT SUB-FRAME WAS CORRODED. THE MANUFACTURER WAS THEN NOTIFIED AND THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 09V124000 (SUSPENSION). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 125,764.

NHTSA ID

10459660

Incident

May 22, 2012

Mileage

125,764 mi

I PURCHASED MY 1999 SONATA FROM A USED CAR DEALER & HAVE HAD NUMEROUS PROBLEMS WITH THE CAR, ITS BEEN A NIGHTMARE, ONE PROBLEM AFTER ANOTHER!!!! THE CRANKSHAFT SENSOR HAD TO BE COMPLETELY REPLACED BECAUSE THE COMPONENT HAD SEVERELY MELTED, ISSUES WITH THE TRANSMISSION, ABS/AIRBAG WARNING LIGHT ON, & HAVE HAD TO CHANGE OUT THE HALF SHAFT ON BOTH DRIVERS/PASSENGER SIDE, NUMEROUS TIRES, BRAKES BUT THE MOST SEVERE OF ALL THE PROBLEMS WHICH PUTS MY SAFETY, MY 12 YR OLD SON & FIANCE'S SAFETY, ALONG WITH FAMILY/FRIEND'S SAFETY AT RISK IS THE COMPLETE CORROSION OF THE SUBFRAME I TOO TO A MECHANIC TODAY & HE TOLD ME TO NOT DRIVE THIS CAR FOR ANYTHING BECAUSE IT WILL RESULT IN AN ACCIDENT WHERE I CAN POTENTIALLY END UP HURTING MYSELF OR OTHER INNOCENT BYSTANDERS BECAUSE HYUNDAI MADE A DEFECTIVE SUBFRAME ESPECIALLY FOR US THAT LIVE & DRIVE IN HAZARDOUS CONDITIONS OF THE WINTRY/ICY ELEMENTS FOR 5+MONTHS OUT OF THE YEAR IN UPSTATE NEW YORK!!! I WILL BE CALLING HYUNDAI'S CUSTOMER ASSISTANCE CTR & FUCCILLO HYUNDAI(LOCAL DEALER)& THE ATTORNEY GENERAL FOR NEW YORK. I CANNOT IMAGINE WHAT COULD'VE HAPPENED IF I DROVE OVER A POT HOLE RESULTING IN MY TIRE(S) FALLING OFF ESPECIALLY IF I WAS ON THE EXPRESSWAY DOING 55MPH MY LOVED ONES OR OTHER'S LOVED ONES, & MYSELF COULD'VE BEEN SEVERELY INJURED OR WORSE DEAD DUE TO HYUNDAI USING A SUBFRAME THAT WOULD SEVERELY CORRODE THE SUBFRAME ESPECIALLY IN THE "SNOW BELT" STATES!!!!! I JUST HOPE THAT I DO NOT HAVE A DIFFICULT TIME HAVING HYUNDAI FIX THE PROBLEM IN A SPEEDY FASHION WITHOUT TRYING TO STRONG ARM ME INTO PAYING FOR REPAIRS THAT I AM NOT RESPONSIBLE FOR BECAUSE IT IS AN INCONVENIENCE BEING WITHOUT A VEHICLE NOW UNTIL IT GETS REPAIRED. *TR

NHTSA ID

10439345

Incident

Oct 1, 2009

Mileage

52,500 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.

Hyundai approves only the ATF, DCT gear oil and IVT gear oil specified in the vehicle’s owner’s manual.  Use of other ATF may result in improper shift quality or other drivability conditions.  Use of other DCT and IVT gear oil may result in reduced durability. Hyundai does not approve the use of any aftermarket ATF or gear oil additives.