The vehicle dossier US · 2003

2003 Hyundai
SONATAProblems & recalls

199 distinct owner reports in the NHTSA snapshot. Other components appears in 46 of them. Explore what was reported—and which official actions are on file.

Snapshot Sep 28, 2026Live NHTSA complaint API How this dossier is compiled

01 / Owner-reported evidence

What owners reported.

Categories attached to 199 distinct reports. A report can mention more than one component, so category totals can overlap.

Other components46 reports
Air bags43 reports
Body & structure38 reports
Electrical system19 reports
Fuel system18 reports
Engine17 reports
Brakes15 reports
Suspension15 reports
Transmission & drivetrain10 reports
Steering9 reports
Visibility5 reports
See original component labels
AIR BAGS34
ELECTRICAL SYSTEM17
SUSPENSION14
STRUCTURE:BODY:DOOR13
STRUCTURE10
STRUCTURE:BODY9
STEERING8
AIR BAGS:FRONTAL8
LATCHES/LOCKS/LINKAGES8
FUEL SYSTEM, GASOLINE8
FUEL/PROPULSION SYSTEM8
POWER TRAIN:AUTOMATIC TRANSMISSION7
ENGINE AND ENGINE COOLING:ENGINE7
WHEELS:HUB7
ENGINE AND ENGINE COOLING6
UNKNOWN OR OTHER6
LATCHES/LOCKS/LINKAGES:DOORS:LATCH5
STRUCTURE:FRAME AND MEMBERS5
SERVICE BRAKES5
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR4
EXTERIOR LIGHTING3
SERVICE BRAKES, HYDRAULIC3
TIRES:VALVE3
SEAT BELTS3
TIRES3
WHEELS3
ENGINE3
SEAT BELTS:FRONT2
POWER TRAIN2
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY2
VISIBILITY:SUN/MOON ROOF ASSEMBLY2
VEHICLE SPEED CONTROL2
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP2
AIR BAGS:SIDE/WINDOW2
SEAT BELTS:FRONT:BUCKLE ASSEMBLY1
VISIBILITY:REARVIEW MIRRORS/DEVICES:INTERIOR1
VISIBILITY:REARVIEW MIRRORS/DEVICES1
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM1
STEERING:COLUMN1
TIRES:TEMPORARY/EMERGENCY SPARE TIRE1
WHEELS:RIM1
VISIBILITY:WINDSHIELD1
VISIBILITY:POWER WINDOW DEVICES AND CONTROLS1
VEHICLE SPEED CONTROL:CRUISE CONTROL1
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD1
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER1
STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS1
AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE1
ELECTRICAL SYSTEM:12V/24V/48V BATTERY1
VISIBILITY1
POWER TRAIN:MANUAL TRANSMISSION1
EQUIPMENT1
SEAT BELTS:FRONT:RETRACTOR1
FUEL SYSTEM, OTHER1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM1
SUSPENSION:REAR1
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC:HOSES, LINES/PIPING, AND FITTINGS1
STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS1
EQUIPMENT:APPLIANCE:AIR CONDITIONER1

These are reports made to NHTSA, not verified diagnoses. More reports can reflect more vehicles, more time on the road, or greater reporting activity.

The reporting timeline

When reports arrived.

Reports by year filed, not by the year a problem occurred. Showing the latest 15 years with reports.

Year filed (last two digits)Latest report: Jun 11, 2026
Mileage, where supplied

65,252 miles is the median among 148 reports with usable mileage. The middle half spans 30,355–106,111 miles.

This describes the submitted reports. It does not predict when a vehicle will fail.

02 / Official safety campaigns

6 recall campaigns on file.

A campaign can cover only certain production dates or configurations. The count does not tell you whether an individual car has an open recall.

Aug 7, 2009 Safety recallLATCHES/LOCKS/LINKAGES:DOORS:LATCHCampaign 09V317000

Reported concern

HYUNDAI IS RECALLING 82 MODEL YEAR 2002-2003 SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATING. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.

Manufacturer’s stated response

DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 16, 2009. OWNERS MAY CONTACT HYUNDAI OF PUERTO RICO AT 1-787-999-3333.

Manufacturer campaign: 91B032

Read campaign 09V317000 at NHTSA
May 21, 2009 Safety recallLATCHES/LOCKS/LINKAGES:DOORS:LATCHCampaign 09V171000

Reported concern

HYUNDAI IS RECALLING 91,350 MY 2002-2003 HYUNDAI SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATE. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING, THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.

Manufacturer’s stated response

DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2009. OWNERS MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

Manufacturer campaign: 093

Read campaign 09V171000 at NHTSA
Apr 16, 2009 Safety recallSUSPENSIONCampaign 09V124000

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: 089

Read campaign 09V124000 at NHTSA
Jul 26, 2004 Safety recallFUEL SYSTEM, GASOLINE:STORAGECampaign 04V369000

Reported concern

CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY" A VALVE ON THE FUEL TANK ASSEMBLY MAY NOT CLOSE PROPERLY. IF A VEHICLE ROLLS OVER AND THE FUEL TANK ASSEMBLY VALVE IS NOT PROPERLY CLOSED, FUEL SPILLAGE MAY OCCUR.

Manufacturer’s stated response

DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. THE RECALL BEGAN ON OCTOBER 5, 2004. OWNERS SHOULD CONTACT HYUNDAI DE PUERTO RICO AT 1-800-981-0188.

Manufacturer campaign: 066

Read campaign 04V369000 at NHTSA
Apr 9, 2004 Safety recallFUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLYCampaign 04V178000

Reported concern

SOME PASSENGER VEHICLES CONTAIN A FUEL TANK ASSEMBLY VALVE THAT MAY NOT CLOSE PROPERLY. IF A VEHICLE WITH A FUEL TANK ASSEMBLY VALVE THAT IS NOT PROPERLY CLOSED WERE TO ROLL OVER, FUEL SPILLAGE MAY OCCUR.

Manufacturer’s stated response

DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. OWNER NOTIFICATION BEGAN ON JUNE 30, 2004. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

Manufacturer campaign: 066

Read campaign 04V178000 at NHTSA
Mar 17, 2003 Safety recallTIRES:TEMPORARY/EMERGENCY SPARE TIRECampaign 03V097000

Reported concern

ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH A TRACTION CONTROL SYSTEM (TCS), IF THE T125/70D-15 COMPACT SPARE TIRE IS INSTALLED ON A FRONT WHEEL POSITION, THE TCS MAY INADVERTENTLY ACTIVATE BEGINNING AT SPEEDS OF 20 MPH.

Manufacturer’s stated response

DEALERS WILL REPLACE THE SPARE TIRE WITH A NEW LARGER DIAMETER T125/80R-15 COMPACT SPARE TIRE AND A NEW TIRE PRESSURE LABEL WILL BE INSTALLED ON THE DRIVER'S DOOR TO PROVIDE INFORMATION APPLICABLE TO THE T125/80R-15 COMPACT SPARE TIRE. VEHICLES PRODUCED FROM NOVEMBER 15, 2002 THROUGH DECEMBER 16 2002, ALREADY CONTAIN T125/80R-15 COMPACT SPARE TIRES, WILL ONLY REQUIRE NEW TIRE PRESSURE LABELS. OWNER NOTIFICATION BEGAN JUNE 30, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

Manufacturer campaign: 059

Read campaign 03V097000 at NHTSA
Check this car’s VIN at NHTSA

03 / The manufacturer’s record

Instructions. Updates. Responses.

76 distinct communications list this model-year. Showing the latest 12. A matching model-year does not establish that every engine, trim or reported symptom is covered.

Apr 10, 2026 OtherDTN DLThe National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN…NHTSA ID 11032523

The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These inflators were not supplied, approved, or authorized by the vehicle manufacturers and have primarily been found in vehicles that previously experienced a crash and underwent airbag replacement using non-genuine parts. These dangerous inflators have ruptured during deployment, posing a serious risk of injury or death due to metal fragments entering the vehicle cabin. To date, Hyundai is aware of three people who have died while driving a Hyundai vehicle with one of these substandard replacement airbag inflators that deployed in what likely would have been a survivable crash. NHTSA has issued a public advisory urging vehicle owners and service professionals to have vehicles inspected if there is reason to believe that a non-genuine replacement airbag may have been installed. Vehicles with salvage or rebuilt titles, prior airbag deployments, or unknown repair histories may present a higher risk. NHTSA strongly cautions against self-inspection by vehicle owners and recommends inspection by trained technicians.

Components: AIR BAGS. Confirm detailed applicability in the original document.

Source record 11032523 at NHTSA
Apr 10, 2026 OtherDTN DCSThe National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co.…NHTSA ID 11032522

The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN), that have been identified in U.S. vehicles following prior crashes, theft, or non‑certified airbag replacements. These inflators are not approved for use, may rupture during deployment, and have caused serious injuries and fatalities. Please see attached announcement, provided by NHTSA, for more details.

Components: AIR BAGS. Confirm detailed applicability in the original document.

Source record 11032522 at NHTSA
Nov 6, 2025 Service Bulletin/Repair Instructions25-BD-012H TSBThis 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 condensat…NHTSA ID 11025476

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.

Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.

Source record 11025476 at NHTSA
Feb 14, 2024 Service Bulletin/Repair Instructions24-BD-001HThis 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 sp…NHTSA ID 10251285

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.

Components: VISIBILITY · VISIBILITY/WIPER. Confirm detailed applicability in the original document.

Source record 10251285 at NHTSA
Oct 13, 2023 Service Bulletin/Repair Instructions23-EM-005HThis bulletin provides important checkpoint guidelines when performing engine oil and filter change services.NHTSA ID 10247189

This bulletin provides important checkpoint guidelines when performing engine oil and filter change services.

Components: ENGINE AND ENGINE COOLING. Confirm detailed applicability in the original document.

Source record 10247189 at NHTSA
Apr 24, 2023 Service Bulletin/Repair Instructions23-BD-007HHyundai 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 pa…NHTSA ID 10235566

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.

Components: STRUCTURE:BODY. Confirm detailed applicability in the original document.

Source record 10235566 at NHTSA
Jan 30, 2023 Service Bulletin/Repair Instructions23-BD-002HThis 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 condensat…NHTSA ID 10230904

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.

Components: VISIBILITY. Confirm detailed applicability in the original document.

Source record 10230904 at NHTSA
Jul 28, 2022 Service Bulletin/Repair Instructions22-EM-010HFollow 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.NHTSA ID 10217251

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.

Components: ENGINE AND ENGINE COOLING. Confirm detailed applicability in the original document.

Source record 10217251 at NHTSA
Jul 14, 2022 Service Bulletin/Repair Instructions22-GI-006HEffective 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 re…NHTSA ID 10217258

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.

Components: TIRES. Confirm detailed applicability in the original document.

Source record 10217258 at NHTSA
May 21, 2021 Service Bulletin/Repair Instructions21-AT-006HHyundai 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…NHTSA ID 10196546

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.

Components: POWER TRAIN. Confirm detailed applicability in the original document.

Source record 10196546 at NHTSA
Mar 30, 2021 Service Bulletin/Repair Instructions21-EM-004HThis bulletin provides the service procedure for engine connecting rod bearing clearance testing. Perform the procedure outlined in this bulletin to fulfill the Bearing Clearance Test inspection requirements to determine next r…NHTSA ID 10190044

This bulletin provides the service procedure for engine connecting rod bearing clearance testing. Perform the procedure outlined in this bulletin to fulfill the Bearing Clearance Test inspection requirements to determine next required steps.

Components: ENGINE AND ENGINE COOLING · EQUIPMENT. Confirm detailed applicability in the original document.

Source record 10190044 at NHTSA
Mar 23, 2021 Service Bulletin/Repair Instructions21-BR-002HThis bulletin provides best practice recommendations when performing brake service procedures.NHTSA ID 10190038

This bulletin provides best practice recommendations when performing brake service procedures.

Components: EQUIPMENT · EQUIPMENT ADAPTIVE/MOBILITY · SERVICE BRAKES. Confirm detailed applicability in the original document.

Source record 10190038 at NHTSA
Browse all manufacturer records by page

Records below contain the NHTSA bulk summary unless a document-reviewed explainer is linked. A service bulletin is not a safety recall or a promise of a free repair. Records may be revised or superseded; verify the current document with the manufacturer.

04 / Agency investigations

Official inquiries.

An investigation is an inquiry into a potential concern. Its presence does not establish a defect, and a closed case does not certify a car’s condition.

Opened Dec 15, 2008 ClosedINTERIOR DOOR HANDLE LACERATION HAZARDPE08071

THE MANUFACTURER HAS ISSUED A SAFETY RECALL NOTIFICATION AS A RESULT OF THIS INVESTIGATION.THE RECALL AFFECTS 91,202 MY 2002-2003 SUBJECT VEHICLES PRODUCED FROM JANUARY 28, 2002, THROUGH MARCH 22, 2003.THE VEHICLE RECALL POPULATION WAS DEFINED BY THE MANUFACTURER'S USE OF A NEW SUPPLIER FOR THE CHROME PLATING PROCESS BEGINNING IN JANUARY 2002, AND A PRODUCTION CHANGE IN MARCH 2003 TO IMPROVE ADHESION OF THE PLATING TO THE DOOR HANDLE.VEHICLES BEING RECALLED REPRESENT 59 PERCENT OF THE TOTAL MY 2002-2003 PRODUCTION, BUT ACCOUNT FOR 91 PERCENT OF THE CONSUMER COMPLAINTS RECEIVED.THE PROCESS CHANGE FOR MY 2002 VEHICLES RESULTED IN A DRAMATIC INCREASE IN COMPLAINTS (1200 PERCENT ON A PER UNIT RATE BASIS).MY 2003 VEHICLES BUILT AFTER MARCH 2003 PRODUCTION CHANGE SHOWED A SIMILAR DECLINE IN THE COMPLAINT RATE.BASED ON THE MANUFACTURER'S ACTION, THIS INVESTIGATION HAS BEEN CLOSED.

Recorded closure: May 29, 2009

Campaign reference in the source: 09V171000

Find investigation PE08071
Opened Aug 21, 2008 ClosedFRONT SUB-FRAME CORROSIONEA08016

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.

Recorded closure: Apr 20, 2009

Campaign reference in the source: 09V124000

Find investigation EA08016
Opened Nov 7, 2005 ClosedTIRE VALVE STEM FAILURESPE05059

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE), PE05-059, BASED ON NINE CONSUMER COMPLAINTS OF TIRE VALVE STEM FAILURES.THE ALLEGED VALVE STEM FAILURES OCCURRED ONLY AFTER TIRE REPLACEMENT FROM THE ORIGINAL EQUIPMENT (OE) TIRE (MICHELIN 205/65R15 ENERGY MXV4 PLUS) TO A NON-OE? AFTERMARKET TIRE.NINETY-EIGHT PERCENT OF THE AFTERMARKET TIRES ALLEGED TO BE ASSOCIATED WITH THE TIRE VALVE STEM FAILURES WERE DETERMINED TO BE AFTERMARKET TIRES PRODUCED BY BRANDS OF MICHELIN GROUP (BF GOODRICH AND UNIROYAL).MICHELIN ISSUED A TECHNICAL BULLETIN ON SEPTEMBER 15, 2005 MAKING RETAILERS AWARE OF A POTENTIAL WHEEL COVER INCOMPATIBILITY WITH BF GOODRICH TRACTION T/AAND TOURING T/A PRO SERIES TIRES THAT COULD CAUSE WHEEL COVER MOVEMENT AND IN EXTREME CASES TIRE VALVE DAMAGE. MICHELIN HAS, ADDITIONALLY, REDESIGNED THE BF GOODRICH AND UNIROYAL TIRES ALLEGEDLY ASSOCIATED WITH THE VALVE STEM FAILURES, AS OF THE FIRST QUARTER OF CALENDAR YEAR 2006. THE PREVIOUS DESIGN VERSION OF BOTH TIRES IS NO LONGER AVAILABLE.NO COMPLAINTS HAVE BEEN SUBMITTED TO ODI FOR TIRES MANUFACTURED AFTER THE INTRODUCTION OF THE REDESIGNED TIRES.THERE HAVE BEEN NO ACCIDENTS, INJURIES OR LOSS OF VEHICLE CONTROL ATTRIBUTED TO THE ALLEGED DEFECT.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Recorded closure: May 11, 2006

Find investigation PE05059

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