Posted on Tuesday 29 April 2008
Over 40 reports of severe corrosion of Hyundai Sonata frames has prompted the U.S. National Highway Traffic and Safety Administration (NHTSA) to investigate the matter. The rust problem is reportedly so severe it is causing suspension failure and ‘fist-sized holes’ in the frame. The problem affects only the 1999-2002 model years (2008 model pictured is not affected).
The immediate symptoms of the problem have been reported to include: “suspension failure, partial or complete wheel detachment, steering anomaly, and/or sudden vehicle disablement,” according to the NHTSA summary of the complaints. Several of the failures have occurred in traffic, although the majority were discovered during mechanics’ inspections.
Buyers of Sonatas with model years 1999 through 2002 have reported ‘fist’-sized holes in the frame according to the NHTSA website. The problem either is more prevalent among the earlier cars, or takes several years to manifest. Of the 40 complaints received by the NHTSA, 19 are for 1999 models, 16 for 2000 models, 3 for 2001 models and 2 for 2002 models.
The focus seems to be on the right side of the frame, especially the right rear corner where the suspension mounts attach. Some reports note the engine cradle, cross-member or front sub-frame, however, so it does not appear to be exclusively localized to the suspension mounts.
A contributing factor is likely the addition of road salt, since 35 of the 40 complaints originate from the so-called ’salt belt’ of northern states that have severe winters.
Via: The Truth About Cars
you should say “2008 models not YET affected”, give it few years to age properly, Hyundai is like a wine.
Well, you should never put salt in a wine. It’s a bad taste.
Its just a case of a bad past catcthing up with you. H has really stepped up their game and while durability is something that I and no one can still attest for on their “new age” models I almost certainly steer it towards it being good in the long run too based on all the other improvements too. Dont think of me as an H fan, I’m well aware prev models were made in very low standards but thats precisely what they want to get out of..
Since November 2006 I have been contacted by 25 different people who have all experienced a failure with the right front subframe rusting apart and actually breaking. Approximately 18 people have been settled with, either Hyundai repairing the car or reimbursing for the repair. Most people have been on the eastern have of the United States. I have been working with an attorney building a case for a class action Lawsuit. We are currently looking for anyone who has had this problem and not contacted me. The NHTSA Number PE08029 is an active investigation that report 40 known failures. I am especial interested in anyone from California.
If you own a 1999-2001 Hyundai Sonata I suggest inspecting your subframe for rust. If you are not sure where to look, you should turn your steering wheel all the way to the right. Look where the A-Arm bolts to the frame. You will probably find severe rust. If you do, I would like to hear from you at tntnknbjuno.com Even if it has not failed yet, I suggest taking it to a Hyundai dealer and filing a claim with Hyundai Consumer affairs.
My hope is that Hyundai, who has admitted to a problem by paying for repairs will soon address this obvious safety issue.
Tom Baker, Kansas City, MO
I have a 2000 Sonata that while being serrviced my mechanic pointed out a fairly significant hole in the right sub frame . he also noted that the transmission cooler line is leaking and the inorder to replace it you must buy the whole radiator assembly. Apparently the eastern seaboard must be hard on this model.