NHTSA Office of Defects Investigation

Engineering Analysis EA08-016: FRONT SUB-FRAME CORROSION

Closed

NHTSA's Office of Defects Investigation opened Engineering Analysis EA08-016 on August 21, 2008, the day it closed Preliminary Evaluation PE08-029, whose summary cites it, and closed it on April 20, 2009. NHTSA's investigations file lists 3 models from 2 makes for it and links recall 09V-124 to it.

Updated daily from NHTSA's investigations file

Key facts

NHTSA number: EA08-016 (also written EA08016)
Investigation type: Engineering Analysis A more detailed stage of a defect investigation, opened when NHTSA's Office of Defects Investigation decides an issue merits further review, often after a Preliminary Evaluation or a Recall Query; it can include vehicle testing, surveys and further information requests.
Status: Closed April 20, 2009
Opened: August 21, 2008
Closed: April 20, 2009
Vehicle or equipment manufacturers: Hyundai Motor America; HYUNDAI CARIBBEAN-PUERTO RICO
Components: Structure; Structure — Frame and Members; Suspension; Suspension — Front; Suspension — Front — Control Arm
Recall linked by NHTSA: 09V-124: FRONT SUB-FRAME CORROSION, reported April 16, 2009
Vehicles and equipment: 3 models from 2 makes, including the Hyundai Sonata and Hyundai Caribbean Sonata

NHTSA's summary

As NHTSA's Office of Defects Investigation wrote it for Engineering Analysis EA08-016.

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.

Vehicles and equipment listed for this investigation

NHTSA's investigations file lists these vehicles and equipment for Engineering Analysis EA08-016. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. Model years with a try.vin recall page link to that page's NHTSA investigations section.

Hyundai

Hyundai Sonata
- 1999, 2000, 2001, 2002, 2003, 2004
Hyundai Sonata GLS
- 1999

All Hyundai recalls

Hyundai Caribbean

Hyundai Caribbean Sonata
- 1999

All Hyundai Caribbean recalls

What an NHTSA investigation is

NHTSA's Office of Defects Investigation (ODI) looks into possible safety defects in vehicles and equipment, often after owner complaints. An investigation usually starts as a Preliminary Evaluation, or as a Recall Query when it concerns whether an existing recall covers the right vehicles or fixes the problem, and ODI can upgrade it to a more detailed Engineering Analysis. A Defect Petition asks NHTSA to open an investigation, and Audit and Equipment Queries are administrative investigations into whether companies complied with federal vehicle safety requirements, such as reporting, recall and certification rules.

An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

To see whether a specific vehicle has an open recall, enter its VIN at nhtsa.gov/recalls.

Free VIN check: decode a VIN to see its year, make and model.

Sources

NHTSA's investigation record for EA08-016

Investigation details come from NHTSA's investigations file, which try.vin imports once a day. The investigation types are described from the U.S. Department of Transportation Inspector General's May 2023 report on NHTSA's Office of Defects Investigation, NHTSA's petition rules (49 CFR Parts 552 and 557) and NHTSA's Office of Defects Investigation procedures. How try.vin reads NHTSA investigations.