2001 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.

Upper rear control arm is connected to the subframe of the car and it’s rotted/ rusted out where the bushing goes to hold the control arm in place. Where am I supposed to mount the bushing now since it’s no longer there.

NHTSA ID

11444930

Incident

Oct 1, 2021

RECENTLY I HAD A SITUATION WHERE I WAS DRIVING ON COUNTY ROAD WAY AND MY CAR SUDDENLY COLLAPSED AND CAME TO AN IMMEDIATE STOP. TO SAY THE LEAST, I WAS A LITTLE SHOOK UP. I GOT OUT THE CAR AND NOTICED THAT THE DRIVER SIDE WHEEL HAD LODGED AGAINST THE WHEEL WELL. THE CAR WOULD GO INTO GEAR BUT IT WAS MAKING A KNOCKING NOISE SO I TURNED IT OFF. A DRIVER OF A GREEN SEDAN CAR WAS BEHIND ME AND I WAS TRYING TO WAVE HER AROUND ME BUT SHE STOPPED AND ASSISTED ME INTO GETTING MY CAR OFF THE STREET BY PUSHING MY CAR WHILE IT WAS IN NEUTRAL. I AM ONLY TELLING YOU THIS BECAUSE THERE WAS NOTHING WRONG WITH MY CAR BEFORE THIS INCIDENT. I WAS TOLD BY HYUNDAI THOMPSON THAT MY CAR WOULD NOT START AFTER IT WAS TOWED THERE. I WENT THERE THE NEXT DAY AND THE CAR DID START BUT IT WOULD NOT GO INTO GEAR WHICH WAS A SURPRISE TO ME. I WAS TOLD THAT THEY MAY HAVE TO CHECK THE TRANSMISSION AND TALK TO YOU TO SEE IF THAT DAMAGE WOULD BE COVER UNDER THE RECALL FOR REPLACING THE ENGINE CRADLE. AFTER HYUNDAI THOMPSON REPAIRED MY CAR I HAD TO TAKE IT BACK FOR A ROARING NOISE CAUSED BY THE WHEEL BEARING IN THE WHEEL THAT JAMMED AGAINST THE WHEEL WELL WHEN THE AXLE SNAPPED OFF THE SUBFRAME. THEY ALSO COULD NOT PREFORM A WHEEL ALIGNMENT. I ALSO TOOK IT FOR A SAFETY INSPECTION AND IT FAILED DUE TO SOME ITEMS I FEEL ARE RELATED TO THE REPAIR OF REPLACING THE SUBFRAME LIKE THE WHEEL BEARING, THE FRONT END ALIGNMENT, BOTH FRONT UPPER CONTROL ARMS AND THE OUTER TIE RODS MISSING COTTER KEYS. I WANT TO KNOW MY RIGHTS CONCERNING THIS RECALL AND I ALSO WANT MY CAR IN THE DRIVING CONDITION BEFORE THIS INCIDENT OCCURRED. CASE # 15551136 WITH HYUNDAI.

NHTSA ID

11220217

Incident

Jan 30, 2019

Mileage

152,565 mi

I WAS DRIVING DOWN MY STREET WHEN THE DRIVERS CV AXLE POPPED OUT OF THE TRANSMISSION. I GOT THE VEHICLE TOWED HOME AND REMOVED THE WHEEL TO FIND THAT THE SUBFRAME WAS CORRODED COMPLETELY INTO. I KNOW THERE ARE RECALLS PERTAINING TO THIS EXACT ISSUE ON THIS TYPE OF CAR

NHTSA ID

11155290

Incident

Sep 25, 2018

Mileage

151,035 mi

CONTROL ARM COMPLETELY SEPARATED/ BROKE FROM THE SUBFRAME. CALLED HYUNDAI AS MECHANIC SAID THIS SHOULD HAVE BEEN INCLUDED UNDER A RECALL THAT CAME OUT SEVERAL YEARS AGO FOR "BECAUSE OF A POTENTIAL CORROSION RISK INVOLVING THE FRONT SUB-FRAME...CORROSION MAY PROGRESS AND THE FORWARD MOUNTING OF THE LOWER CONTROL ARM MAY DETACH FROM THE SUB-FRAME. IF THAT HAPPENS, THE VEHICLE MAY LOSE DRIVER POWER TO THE WHEELS. THE FRONT WHEEL MAY MAKE CONTACT WITH THE FENDER OR WHEEL WELL." "SEPARATION OF THE FORWARD MOUNTING OF THE LOWER CONTROL ARM MAY INCREASE THE RISK OF A CRASH" THIS IS EXACTLY WHAT HAPPENED TO MY 17 YEAR OLD DAUGHTER YESTERDAY AND FORTUNATELY SHE DID NOT CRASH AS SHE WAS NOT IN A POPULATED AREA, BUT IT COULD HAVE BEEN MUCH WORSE. WHY IS THIS PARTICULAR 2001 HYUNDAI SONATA NOT COVERED UNDER THIS RECALL. IT NEEDS TO BE COVERED AND COVERED ASAP. PLEASE ASSIST. VEHICLE IS CURRENTLY AT COLUMBIA FAMILY AUTO CARE IN JESSUP MD 301-362-0777

NHTSA ID

11113063

Incident

Jul 22, 2018

Mileage

130,000 mi

AIRBAG RED LIGHT COMES ON WHEN STARTING THE ENGINE. RESTRAINING STRAP IN REAR-LEFT SEAT DOES NOT ENGAGE.

NHTSA ID

11110104

Incident

Jul 8, 2008

Mileage

66,667 mi

TL* THE CONTACT OWNS A 2001 HYUNDAI SONATA. WHILE THE VEHICLE WAS PARKED AND UNOCCUPIED, THE DRIVER'S SIDE AIR BAG DEPLOYED WITHOUT WARNING OR IMPACT. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THE LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE AND VIN WERE UNKNOWN.

NHTSA ID

11075013

Incident

Feb 24, 2018

TL* THE CONTACT OWNS A 2001 HYUNDAI SONATA. WHILE MAKING A RIGHT TURN, THERE WAS AN ABNORMAL NOISE COMING FROM THE FRONT PASSENGER SIDE TIRE. IT WAS DISCOVERED THAT THE CONTROL ARM HAD FRACTURED FROM THE FRAME, WHICH WAS CRUMBLING DUE TO RUST AND CORROSION. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING AND THEN TOWED TO THE CONTACT'S RESIDENCE AND TO THE DEALER (HYUNDAI OF CHANTILLY, 14848 STONECROFT CENTER CT, CHANTILLY, VA 20151, (703) 480-9000). THE CONTACT WAS NOT SURE IF THE VEHICLE WAS INCLUDED OR EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE MANUFACTURER WAS TO PROVIDE A FOLLOW-UP RESPONSE TO DETERMINE THEIR SOLUTION FOR THE DEALER'S REPAIR. THE VEHICLE WAS UNABLE TO BE DRIVEN DUE TO THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 133,000.

NHTSA ID

11057343

Incident

Sep 4, 2017

Mileage

133,000 mi

PASSENGER SENSOR RIGHT FRONT,SENSOR FOUND IT FAULTY,THIS SENSOR IS UNDER THE FABRIC OF SEAT.LIGHT IS ALL WAYS ON.

NHTSA ID

10967070

Incident

Feb 7, 2017

Mileage

114,259 mi

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.

This bulletin contains information about the proper removal of the windshield wiper blade protective cover on all models. If the protective cover is not removed correctly, there is a possibility of the rubber insert and rail spring becoming partially separated on the inner side of the wiper blade, which could lead to poor wiping performance and/or possible scratching of the windshield glass. Follow the procedure in this bulletin to properly remove the windshield wiper blade protective cover on all new wiper blades.

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.