NHTSA Complaint #10824312 — 2012 HYUNDAI SONATA

THE ENGINE OIL PAN WAS RESEALED FIVE TIMES AND STILL ITS LEAKING. WHEN THEY RESEALED THE SECOND TIME, THEY REPLACED THE OIL PAN AS WELL. AFTER THAT IT WAS RESEALED THREE MORE TIMES AND THE CAR IS AT THE DEALER FOR SIXTH RESEAL. THEY ARE REPLACING THE PAN AGAIN. THE BRAKE CALIPER PISTONS ARE EXHIBITING EXCESSIVE RUST WHICH I HAVE NOT SEEN IN MY LIFE WHILE OWNING AND MAINTAINING VARIOUS CARS. THE FIELD ENGINEER IS SAYING THAT ITS NORMAL AND I DON'T AGREE WITH THAT. WHAT I HAVE SEEN BASED ON THAT IT'S A DESIGN FLAW. THE CALIPER PISTON SHOULD BE PRESSING COMPLETELY AGAINST THE BRAKE PAD SURFACE AREA WHERE AS SMALL PORTION OF THE CALIPER REMAINS IN NON CONTACT WITH THE PAD AND THE SALT AND SLUSH DURING THE WINTER GETS INTO IT MAKING IT RUST WHICH WILL IMPEDE THE BRAKING OPERATION IN FUTURE AND MAY CAUSE A FATAL CRASH. ATTACHED PHOTOGRAPHS ARE SHOWING PACK RUST INSIDE THE PISTON ON BOTH THE DRIVER AND PASSENGER SIDE.