2003 HYUNDAI SONATA Structurebody Problems

NHTSA Campaign ID Number: 09V124000 NHTSA Action Number: EA08016 Recall calls for repair or replacement of front sub-frame, due to corrosion. Local dealer responded, “ . . . we will not be able to perform recall”. I was told the corrosion was too far gone to repair. They refuse to replace the defective part.

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH AND MAKING A RIGHT TURN, THERE WAS A LOUD NOISE COMING FROM THE VEHICLE. IN ADDITION, THE VEHICLE BEGAN TO SHAKE VIOLENTLY. UPON INSPECTION, IT WAS DISCOVERED THAT THE SUB FRAME HAD FRACTURED DUE TO RUST AND CORROSION. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 139,000.

2003 HYUNDAI SONATA AFFECTED BY PROGRESSIVE, INTERNAL CORROSION OF THE RIGHT FRONT SUB-FRAME ON THE VEHICLE, AND RESULTING IN THINNING, RUSTING OR PERFORATION OF THE SUB-FRAME STEEL. THE CORROSION/RUST IS VISIBLE AND DISCOVERED DURING INSPECTION & ROUTINE MAINTENANCE, AND ALSO HEAR NOISES & NOTICE TIRE MISALIGNMENT AND STEERING PULL.THESE SIGNALS ARE DETECTING THE CORROSION PROGRESSING AND THE FORWARD MOUNTING OF THE LOWER CONTROL ARM DETACHING FROM THE SUB-FRAME. THE VEHICLE WAS BOUGHT NEW IN NEBRASKA, AND HAS REMAINED IN NEBRASKA ITS ENTIRE LIFE. NEBRASKA USES SALT ON ITS ROADS IN THE SAME CAPACITY AS IOWA AND OTHER "SALT STATES". SUCH CARS SHOULD BE INCLUDED IN THE RECALL WHEN CONSIDERING THE LACK OF SAFETY AND DANGERS INVOLVED WHEN THE SUBFRAME DETERIATES DUE TO DEFECTS IN THE MANUFACTURE OF SAID CAR. HYUNDAI SHOULD HONOR AND EXTEND THE RECALL OF SAID CAR IN THE STATE OF NEBRASKA BECAUSE THE DEFECT IN THE SUBFRAME...

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. CONSEQUENCE: THIS MAY INFLICT LACERATION INJURIES TO ANYONE USING THE DOOR HANDLE. BASICALLY WHEN YOU GO TO USE THE INSIDE DOOR HANDLES THE PEELING CHROME IS SHARP AND CUTS YOUR FINGERS. HYUNDAI RECALL #93 ENDED IN MARCH 2003, MY CAR WAS MANUFACTURED IN MAY 2003. THE PROBLEM IS IDENTICAL TO THE MODELS IN RECALL #93.

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. WHEN THE VEHICLE WAS TAKEN TO BE INSPECTED, THE INSPECTOR OBSERVED THAT THE SUBFRAME WAS SEVERELY CORRODED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE FAILURE MILEAGE WAS UNKNOWN.

IN 2005, I PURCHASED A 2003 HYUNDAI SONATA. AFTER PURCHASING MY CAR, I FOUND OUT THAT IT HAD A RECALL ON THE FUEL VALVE THAT THE COMPANY HAD TO RE-INSTALL. THIS RECALL INFORMATION WAS NOT ON MY CARFAX REPORT. LATER, THE MANUFACTURER HAD A RECALL ON INTERIOR DOOR HANDLES THAT PEELED AND CUT HANDS. THEIR SOLUTION WAS TO WRAP MY HANDLES WITH ELECTRICAL TAPE; AFTER MY OBJECTION, THEY INSTALLED THE SAME RECALLED HANDLES. I'VE HAD MY INTERIOR HANDLES REPLACED THREE TIMES BECAUSE THE MANUFACTURER DIDN'T MAKE THE HANDLES OUT OF A DIFFERENT MATERIAL AND CHOOSES TO REINSTALL THE SAME RECALLED HANDLE. ON NOVEMBER 22ND, I WENT TO CAPITOL HYUNDAI TO HAVE THEM REPLACE THE RECALLED FUEL VALVE, AND INTERIOR DOOR HANDLES ON MY 2003 HYUNDAI SONATA. A SERVICE REP INFORMED ME THAT ONCE THE COMPANY REPLACES ANY RECALLED ITEMS THE FIRST TIME, IT IS THE CUSTOMER'S RESPONSIBILITY TO PAY FOR...

CHROME ON INTERIOR DOOR HANDLES PEELS AND CREATES LACERATION HAZARD. THE MANUFACTURER ISSUED A RECALL TO REPLACE AFFECTED HANDLES BECAUSE OF A STATED LACERATION HAZARD. THE DEALER REPLACED HANDLES UNDER THE RECALL. HOWEVER, THE REPLACEMENT HANDLES ARE NOT AN IMPROVED PRODUCT AND THE CHROME PEELS LIKE THE ORIGINALS. THE DEALER ONLY ALLOWS ONE REPLACEMENT UNDER THE RECALL, WHICH CREATES A CONTINUING HAZARD TO THE OWNER AND PASSENGERS. *TR

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, HE HEARD A LOUD, ABNORMAL NOISE. THE CONTACT PULLED OVER AND INSPECTED THE VEHICLE WHEN HE NOTICED THAT THE SUB FRAME WAS FRACTURED. THE VEHICLE WAS LATER TOWED TO AN INDEPENDENT MECHANIC WHERE THEY CONFIRMED THAT THE FRONT SUB FRAME WAS FRACTURED AND ALSO ADVISED THAT IT NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 160,000.

VEHICLE HAD BEEN RECALLED IN 2009 (PE08071) DUE TO DEFECTIVE CHROME ON DOOR HANDLES. THIS VEHICLE HAD BEEN TAKEN TO DEALERSHIP, CHROME WAS REPAIRED AS IT HAD CAUSED A SMALL LACERATION. CHROME IS AGAIN DEFECTIVE, CAUSED LACERATION ON HAND AGAIN TODAY WHEN ATTEMPTED TO OPEN DOOR. THIS OCCURRED ON THE PASSENGER SIDE DOOR WHICH IS VERY RARELY USED. CHROME IS ALSO PEELING OFF OF EMERGENCY BRAKE HANDLE, RISKING FURTHER LACERATION. CONTACTED DEALERSHIP (GO HYUNDAI - 104TH & FEDERAL, WESTMINSTER, CO), DEALERSHIP SAID THIS IS NO LONGER COVERED AS THEY DO NOT WARRANTY THE WORK DONE AS PART OF A RECALL. IN ADDITION, CAR IS TOO OLD FOR IT TO BE COVERED UNDER WARRANTY. CAR DOES CONTINUE TO BE COVERED UNDER WARRANTY FOR POWERTRAIN ONLY. I HAVE NEVER EXPERIENCED THIS TYPE OF PROBLEM ON ANY MODEL OF CAR REGARDLESS OF AGE. THIS APPEARS TO BE UNIQUE TO HYUNDAI. *JS