The defect
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.
The risk
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.
The 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.
NHTSA's own wording · initiated by ODI
Vehicles covered
| Model | Model years |
|---|---|
| Hyundai Sonata | 1999, 2000, 2001, 2002, 2003, 2004 |
| Hyundai XG300 | 2001, 2002, 2003, 2004 |
| Hyundai XG350 | 2001, 2002, 2003, 2004 |
Components: SUSPENSION
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| Hyundai Sonata | 1999 | 124 | 4 |
| Hyundai Sonata | 2000 | 276 | 4 |
| Hyundai Sonata | 2001 | 205 | 3 |
| Hyundai Sonata | 2002 | 320 | 7 |
| Hyundai Sonata | 2003 | 199 | 6 |
| Hyundai Sonata | 2004 | 202 | 1 |
| Hyundai XG300 | 2001 | 65 | 4 |
| Hyundai XG300 | 2002 | 1 | 1 |
| Hyundai XG300 | 2003 | 8 | 1 |
| Hyundai XG300 | 2004 | 1 | 1 |
| Hyundai XG350 | 2001 | 3 | 1 |
| Hyundai XG350 | 2002 | 60 | 3 |
| Hyundai XG350 | 2003 | 20 | 3 |
| Hyundai XG350 | 2004 | 44 | 1 |
Other suspension recalls in 2009
15 of the 491 recall campaigns reported to NHTSA in 2009 concerned the suspension; Hyundai Motor Company filed 32 campaigns in all.
| 09V458000 1 Dec 2009 | DAIMLER TRUCKS NORTH AMERICA |
| 09V378000 2 Oct 2009 | TRIUMPH MOTORCYCLES AMERICA LTD |
| 09V358000 16 Sept 2009 | NISSAN NORTH AMERICA, INC. |
| 09V200000 8 Jun 2009 | MOTOR COACH INDUSTRIES, INC |
| 09V183000 27 May 2009 | KIA MOTORS CORPORATION |
| 09V123000 16 Apr 2009 | Hyundai Motor Company |
| 09V125000 16 Apr 2009 | Hyundai Motor Company |
| 09V119000 9 Apr 2009 | CHRYSLER LLC |
NHTSA recalls (public domain) · all recalls of 2009