NHTSA Complaint #10200055 — 1999 HYUNDAI SONATA GLS

APPROACHING A STOP SIGN AT AN INTERSECTION NEAR WORK, THE CAR MADE A LOUD KIND OF CRUNCHING NOISE AND CAME TO A SUDDEN STOP. I NOTICED THAT MY CAR WAS LEANING DOWN A LITTLE IN THE FRONT ON THE RIGHT SIDE. FROM INSIDE IT LOOKED LIKE I HAD A FLAT, BUT WHEN I GOT OUT OF THE CAR TO CHECK I NOTICED THAT THE RIGHT FRONT TIRE WAS LEANING OUT TOWARDS THE CURB AND APPEARED TO HAVE BROKEN OFF. I TRIED TO MOVE THE CAR TO THE SIDE OF THE STREET, BUT IT WOULDN'T MOVE. I EVENTUALLY HAD MY CAR TOWED TO A LOCAL MECHANIC. I WAS INFORMED BY THE MECHANIC THAT THE LOWER CONTROL ARM HAD ROTTED AWAY FROM THE SUBFRAME. SINCE I HAD AN EXTENDED WARRANTY, BUMPER-TO-BUMPER, I CALLED THE COMPANY, UNIVERSAL UNDERWRITERS SERVICE CORPORATION. THEY LATER INFORMED MY MECHANIC THAT THEY WOULDN'T COVER ANYTHING BECAUSE THE SUBFRAME WAS NOT INCLUDED AS A COVERED PART AND ALSO BECAUSE THE DAMAGE WAS CAUSED BY CORROSION AND CORROSION VOIDS ALL COVERAGE. I THEN CONTACTED THE HYUNDAI DEALER WHO ALSO TOLD ME THE SAME THING. IT COST ME $2000 TO GET THE CAR FIXED. WHEN I WENT TO PICK UP THE CAR, THE MECHANIC SHOWED ME THE OLD SUBFRAME AND WHERE IT HAD ROTTED OUT AND I COULDN'T BELIEVE WHAT I WAS LOOKING AT. YOU COULDN'T EVEN SEE WHERE THE TWO HOLES THAT THE LOWER CONTROL ARM BOLTS INTO WERE. THERE WERE JUST TWO BIG GAPING HOLES SURROUNDED BY RUSTED METAL. HE TOLD ME THAT THE NEW SUBFRAME HAD THREE DRAIN HOLES ON BOTH SIDES OF THE SUBFRAME THAT WOULD ALLOW WATER TO DRAIN OUT. BECAUSE THE OLD SUBFRAME DIDN'T HAVE ANY DRAIN HOLES, HE FELT THAT THIS MEANT THAT HYUNDAI MADE THE CHANGES FOR SOME REASON. HE ALSO MENTIONED THAT I WAS LUCKY THAT THIS DIDN'T HAPPEN TO ME WHILE I WAS DRIVING FASTER ON A MAJOR HIGHWAY. I HAVE FOUND OTHER SONATA OWNERS ON THIS SITE WITH THE SAME PROBLEM. I AM CONCERNED FOR OTHER SONATA OWNERS WHO MAY BE DRIVING A PRODUCT WITH A CLEAR MANUFACTURE FLAW. THIS LOOKS LIKE A SAFETY CONCERN FOR THE OWNER AND FOR OTHERS ON THE ROAD. I CURRENTLY HAVE THE PART IN MY GARAGE. *TR