2003 Hyundai Elantra SUSPENSION,STRUCTURE

*The rear sub-frame assembly nearly rusted through. Steering and Handling noticebly effected with rear of vehicle feeling soft and sluggish in turns. *The vehicle is available for inspection and was brought to my attention when the mechanic was beginning rear brake maintenance. *The mechanic is a licensed mechanic and the Repair shop is a licensed service facility. *The mechanic called me and asked me to return to the shop to show me the extent of the rust damage, to which I did return to the shop to examine his findings. I did take photos. *There were no warning lamps or messages. The symptoms were as described above.

MY REAR SUBFRAME IS RUSTING SO BADLY THE REAR SUSPENSION IS FALLING APART.

OUR 2003 HYUNDAI ELANTRA IS SUFFERING FROM SEVERE CORROSION ON THE SUBFRAME/UNIBODY, A PROBLEM FOR WHICH A CLASS ACTION SETTLEMENT WAS APPROVED (SEE THE FOLLOWING LINK HTTP://SALTBELTCORROSION.HYUNDAIUSA.COM/ FOR DETAILS REGARDING THE CIRULLI V. HYUNDAI MOTOR AMERICA SETTLEMENT, WHICH REACHED FINAL APPROVAL ON MAY 25, 2011). THE SETTLEMENT PROVIDED REIMBURSEMENT FOR REPAIRS. ALTHOUGH HYUNDAI PERFORMED A "RUSTPROOFING/WAX" REPAIR IN 2010 ON THIS CAR, AS WELL AS A SUBFRAME REPAIR/REPLACEMENT IN 2015 (WHICH IS CONSIDERED BY HYUNDAI TO HAVE SOLVED THE PROBLEM AS ORIGINALLY DESCRIBED IN THE CLASS ACTION LAWSUIT), WE BELIEVE THAT THE DEFECT AS DESCRIBED IN THE CLASS ACTION SETTLEMENT WAS IN FACT NOT RECTIFIED, AND THUS CONSISTS OF A FAILURE OF RECALL REPAIR. IN FACT, IT WOULD SEEM THAT ALTHOUGH HYUNDAI DID REPLACE ALL OR A PORTION OF THE SUBFRAME IS 2015, THE EXACT SAME PROBLEM HAS RE-OCCURRED ON THE CAR WITHIN LESS THAN 5 YEARS, AND IS A SERIOUS SAFETY ISSUE (IF THE SUBFRAME COLLAPSES UNDER THE WEIGHT OF THE CAR, THERE WOULD BE SERIOUS RISKS OF INJURY TO ANY PASSENGERS ON BOARD). THE DEEP SUBFRAME CORROSION ITSELF WAS ONLY NOTICED AND PHOTOGRAPHED BY A LOCAL MECHANIC MORE THAN A YEAR AFTER PURCHASING THIS VEHICLE FROM ITS SECOND OWNER AND IS EVIDENCED BY THE ATTACHED PICTURES. IN SUMMARY, ALTHOUGH HYUNDAI MOTOR AMERICA CONSIDERS THAT THE CORROSION PROBLEM AS DESCRIBED IN CIRULLI V. HYUNDAI MOTOR AMERICA SETTLEMENT WAS REPAIRED SUCCESSFULLY IN 2015 ON THE CAR CORRESPONDING TO THE VIN NUMBER ATTACHED TO THIS COMPLAINT, WE BELIEVE THAT IT CONSISTED OF A FAILED RECALL REPAIR, AND THAT IT IS THE RESPONSIBILITY OF HYUNDAI MOTOR AMERICA TO RECTIFY THE SITUATION AT THEIR EXPENSE. ALSO ATTACHED IS A PDF SHOWING A DESCRIPTION OF THE CORROSION WITHIN A LARGER ESTIMATE, WHICH WAS AUTHORED BY THE SAME SHOP THAT TOOK THE PHOTOS OF THE VEHICLE'S CORRODED SUBFRAME.

2003 HYUNDAI ELANTRA. CONSUMER WRITES IN REGARDS TO PASSENGER SIDE CONTROL ARM CORROSION RECALL REIMBURSEMENT. *SMD *TR

THE WHOLE REAR METAL BEAM HOLDING THE REAR SUSPENSION RUSTED OUT AND FELL OFF WHILE DRIVING SENT CSRD INTO A SPIN BEFORE WE GOT IT STOPPED COULD HAVE BEEN KILLED DRIVING ON INTERSTATE 70 FROM WARRENTON TO WENTZVILLE MO YESTERDAY MOURNING AT 5:30 AM. *TR

IN 2009, A RECALL WAS ISSUED FOR RUST/CORROSION OF THE FRONT LOWER CONTROL ARMS OF THESE VEHICLES (RECALL 091 PER HYUNDAI). WE FOUND OUT ABOUT THIS AND TOOK IT TO OUR LOCAL DEALER IN 2011. HOLES WERE DRILLED AND THE CAR "PASSED" WITHOUT NEED TO REPLACE ANYTHING. A "PROTECTIVE COATING" WAS APPLIED. ON SATURDAY, MAY 3, MY HUSBAND WAS DRIVING AND PULLING OUT OF A PARKING SPACE. HE HEARD A GRINDING NOISE AS HE BACKED OUT, THEN HEARD SOMETHING BREAK AND THE CAR WOULDN'T MOVE. WE COULDN'T EVEN PUSH THE CAR BACK INTO THE PARKING SPACE, AS THE TIRE/ARM APPEARED TO BE DETACHED. WE FOUND OUT THE RIGHT CONTROL ARM HAD RUSTED THROUGH COMPLETELY, ALSO CAUSING DAMAGE OF THE AXLE. THE CAR WAS TAKEN FIRST TO OUR MECHANIC AND THEN THE DEALERSHIP AND IT WAS DETERMINED THE SAME RECALLED PART HAD RUSTED THROUGH, CAUSING THE BREAK. THE CAR WAS FIXED BY HYUNDAI, INCLUDING REPLACEMENT OF BOTH CONTROL ARMS. I'M JUST VERY CONCERNED THAT THIS COULD HAVE OCCURRED WHILE DRIVING AND CAUSED A CRASH AND SERIOUS INJURY. WE HAD NO IDEA OF THE RISK, ALTHOUGH WE DID HAVE A BAD WINTER WITH A LOT OF ROAD SALT USED SO I'M NOT SURPRISED. I AM SURPRISED, THOUGH, THAT IT WAS NEVER ADVISED TO RETURN AND HAVE THIS RE-CHECKED. I CALLED HYUNDAI'S CARE MANAGEMENT DEPT AND THE PERSON I SPOKE WITH ([XXX]) DENIED THIS ISSUE WAS RELATED TO THE RECALL AND SAID IT MUST HAVE BEEN REPAIRED ONLY AS A COURTESY. I STRONGLY DISAGREE BY WHAT I HEARD FROM THE MECHANIC. I WANTED TO MAKE YOU AWARE AS I'M SURE THE SAFETY OF MANY IS AT RISK IF THIS A RESULT OF A RECALLED PART AND THEY ARE UN-KNOWINGLY AT RISK AFTER THIS BAD WINTER. THANK YOU. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

THANKFULLY NO INCIDENT, MY MECHANIC POINTED OUT TO ME DURING NORMAL MAINTENANCE ON THE CAR, THE LOWER CONTROL ARM HAD SEVERE CORROSION DAMAGE THAT ITS ALMOST SPLIT HE ADVISED NOT TO TAKE IT ON THE HIGHWAY UNTIL IT WAS FIXED. HE PRINTED OUT THE RECALL NOTICE OF THE PROBLEMS WITH THE FRONT LOWER CONTROL ARM. HYUNDAI IS GIVING ME PUSH BACK ON TAKING CARE OF IT BECAUSE IM NOT IN THE SALT BELT. I AM NOT IN A SALT FREE STATE THEY SALT HEAR AT THE THREAT OF FLURRIES. THAT KIND OF DAMAGE IS NOT NORMAL WEAR AND TEAR ON A CAR THAT'S UNDER 60K MILES. I DON'T WANT THE WORLD I JUST WANT THEM TO FIX THE DEFECTIVE PRODUCT, MORE IMPORTANT THAN THAT HAD MY MECHANIC NOT POINTED IT OUT I COULD HAVE PUT MYSELF OR OTHERS IN DANGER IF THIS SNAPPED AND I LOST CONTROL OF THE PASSENGER SIDE WHEEL. I CANT BE THE ONLY ONE OUTSIDE OF THE SALT BELT THAT IS HAVING THIS ISSUE AND MAY BE IN DANGER IF IT SEPARATES. THANK YOU FOR TAKING THE TIME TO LISTEN. *TR

AS I WAS DRIVING MY 2003 HYUNDAI ELANTRA OUT OF WORK, THE STRUCTURAL METAL COMPONENT THAT CONNECTS TO THE FRONT, PASSENGER SIDE TIRE (OR REFERRED TO AS LOWER ARM OR A-FRAME) SNAPPED AND THE VEHICLE LOST CONTROL AND STOPPED MOVING IMMEDIATELY. THE TIRE WAS ESSENTIALLY DETACHED FROM THE VEHICLE AND DAMAGE TO THE PASSENGER SIDE DOOR, FRONT BUMPER AND WHEEL COVER. THANK GOODNESS I WAS NOT ON A MAIN ROAD YET IN RUSH HOUR TRAFFIC DRIVING 40-50 MPH OR I AM CERTAIN THERE WOULD HAVE BEEN AN ACCIDENT WHEN I WOULD HAVE LOST CONTROL OF THE VEHICLE DUE TO THIS LATENT STRUCTURAL DEFECT. I HAD THE TRUCK TOWED TO THE NEAREST HYUNDAI DEALER TO BE EXAMINED AND TOOK PHOTOS OF THE CONDITION OF THE RUSTED METAL CONTROL ARM THAT HAD SNAPPED. I DID SOME RESEARCH ON RECALLS WITH THIS VEHICLE AND THERE WAS A 4/2009 RECALL IN CERTAIN STATES WITH HEAVY WINTERS AND USE OF SALT TO CLEAR ROADS, ETC. MY STATE (NEBRASKA) WAS NOT LISTED AS AN AFFECTED STATED BUT ALL OF THE SURROUNDING STATES (I.E. IOWA, MINNESOTA, MISSOURI, ILLINOIS, INDIANA, COLORADO, WISCONSIN) WERE. NEBRASKA HAS JUST AS MUCH SNOW OR MORE SNOW THAN IOWA IN MY OPINION. THE VEHICLE WAS ORIGINALLY PURCHASED IN OMAHA, NE WHICH IS RIGHT ON THE BORDER OF IOWA. I BELIEVE THIS WILL ALSO BE A PROBLEM IN NEBRASKA AND SURROUNDING STATES POSSIBLY. IF THIS CONTROL ARM SNAPS WHILE SOMEONE IS DRIVING ON THE INTERSTATE OR OTHER ROADS AT HIGHER SPEEDS, SOMEONE WILL BE SERIOUSLY INJURED. I AM EVEN MORE UPSET BY THE FACT THAT MY ONE YEAR OLD SON VERY WELL COULD HAVE BEEN IN THE VEHICLE WITH ME WHEN THIS HAPPENED. NOT GOOD. THANKFULLY, NO ONE WAS INJURED AND THE ONLY DAMAGE WAS TO THE VEHICLE ITSELF. THE DEALER CALLED TODAY AND THEY EXPLAINED WE ARE NOT A PART OF THE RECALL BUT THE EVIDENCE IS PRETTY OBVIOUS THAT THIS IS THE SAME IDENTICAL PROBLEM AND THEY ARE TRYING TO USE ARBITRARY STATE BOUNDARIES TO GET OUT OF THEIR RESPONSIBILITY. WE ALSO CARRY A FULL WARRANTY UNTIL 2013 ON THE VEHICLE SO WE WILL SEE WHAT HAPPENS. *TR

I OWN A 2003 HYUNDAI ELANTRA GT THAT CURRENTLY HAS ABOUT 58000 MILES ON IT. WHILE DRIVING HOME, WHEN I WAS APPROX 2 MILES AWAY I NOTICED THAT THE CAR STARTED TO PULL TO ONE SIDE A BIT. THINKING IT WAS A FLAT, I DROVE SLOW FOR THE REMAINING MILE OR SO AND WHEN I WAS ABOUT 200 YARDS FROM MY DESTINATION, THE FRONT END DROPPED AND THE CAR STOPPED. UPON VISUAL INSPECTION, IT LOOKS LIKE THE FRAME WHERE THE PASSENGER FRONT TIRE MEETS THE STEERING ROD COMPLETELY ROTTED THROUGH AND BROKE. AFTER LOOKING ON THE WEB, IT SEEMS VERY SIMILAR TO INVESTIGATION PE09011. *TR

I WAS DRIVING DOWNHILL TO A STOP SIGN (FROM ABOUT 20MPH), AND PRESSED THE BRAKE PEDAL, AT WHICH POINT I HEARD AN AWFUL CRUNCH NOISE, AND THE FRONT RIGHT CORNER OF MY CAR JOLTED, SHOOK, AND SOUNDED LIKE SOMETHING WAS GRINDING TOGETHER. I GOT OUT OF THE CAR TO LOOK AT THE FRONT RIGHT WHEEL, AND SAW THAT IT WAS TURNED IN TOWARDS THE CENTER OF THE CAR, AND BENT UNDER THE FRONT OF THE CAR, ABOUT 1/4" AWAY FROM THE BACK OF THE WHEEL WELL, WHILE MY OTHER FRONT WHEEL WAS AIMED STRAIGHT AHEAD. I DROVE THE CAR 100 FEET TO A SAFE PLACE OFF THE STREET, DURING WHICH TRIP THE STEERING WHEEL TRIED TO SPIN WILDLY IN VARIOUS DIRECTIONS, AND THE CRUNCHING, JOLTING NOISES AND MOTIONS CONTINUED. THE CAR WAS NOT DRIVABLE, SO I CALLED A FLATBED TOW TRUCK, WHO TOWED IT TO MY MECHANIC.. WHEN THE MECHANIC WAS ABLE TO LOOK AT THE VEHICLE, HE DETERMINED THAT THE CONTROL ARM HAD COMPLETELY SNAPPED IN HALF, AS A RESULT OF RUST CORROSION FROM THE INSIDE OUT. VISUAL INSPECTION OF THE CONTROL ARM CONFIRMED THAT THE METAL IT IS CONSTRUCTED OUT OF WAS CORRODED DOWN TO A THICKNESS OF APPROXIMATELY 5 OR 6 SHEETS OF PAPER. WATER KICKED UP FROM WET ROADS BY THE TIRES HAD GOTTEN INSIDE THE CONTROL ARM (THROUGH A FAULTY SEAL) AND, AS THERE ARE NO DRAINAGE HOLES IN THE CONTROL ARM, IT REMAINED INSIDE, EATING AWAY AT THE METAL UNTIL FINALLY THE WEIGHT OF THE CAR SNAPPED THE ARM IN HALF. THIS FAILURE OF THE CONTROL ARM ALSO WRECKED THE SUSPENSION OF THE CAR, AS WELL AS THE CV SHAFT, THE RIGHT FRONT AXLE, AND THE SWAY BAR LINKS. THE CONTROL ARM, THE CV SHAFT, AND THE SWAY BAR LINKS HAD TO BE COMPLETELY REPLACED, AND THE CAR NEEDED A REALIGNMENT. *TR