2005 Hyundai Sonata Suspension

The contact owns a 2005 Hyundai Sonata. The contact stated that while her daughter was driving at 45 MPH, the vehicle rode over a pothole which caused a fracture in the subframe. The contact had taken the vehicle to several independent mechanics and was informed that the failure was caused by severe salt corrosion. The dealer and the manufacturer were notified of the failure and informed her that there were no recalls associated with the VIN. The vehicle was not repaired. The failure mileage was approximately 134,000. Consumer stated part# FC112 is used for 2003, 2004 AND 2005. 2003 AND 2004 of the same make and model are already recalled for the same issue with the subframe having rust due to excessive salt exposure, but SOMEHOW the 2005 which is EXACTLY the same part and problem has not been recalled.

My mechanic just took a picture of the subframe of the car which is almost completely rusted through. He said that this is extremely dangerous and that if it was to break while driving the car, I would loose control. I have seen numerous complaints about this on the 2005 Hyundai Sonata on the internet which makes me think this is a common issue.

I had taken my 2005 Hundai Sonata to my local mechanic for a tire alignment, and it is then when I was told that the front subframe was rusted from the inside. There was no indicator of this beforehand, and had it been let be, I could have lost control of the car while driving and been in an accident.

The contact owns a 2005 Hyundai Sonata. The contact stated while having a state inspection performed, the inspector informed the contact that the sub-frame was completely rusted. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 09V124000 (Suspension) however, the VIN was not included. The manufacturer was informed of the failure and informed the contact that the vehicle was not included in a recall. The failure mileage was approximately 129,000.

2005 HYUNDAI SONATA FRONT SUB-FRAME FAILURE. THE SUB FRAME HAS RUSTED THROUGH AND WHILE DRIVING IT BROKE. THIS COULD HAVE CAUSED A TERRIBLE ACCIDENT. HYUNDAI WAS SUED IN A CLASS ACTION LAWSUIT FOR MODEL YEARS 1999-2004 IN UNITED STATES DISTRICT COURT OF CALIFORNIA. MY MODEL YEAR WAS NOT INCLUDED IN THIS LAWSUIT. HOWEVER, MY SONATA HAS THE SAME ISSUE. I HAVE MADE SEVERAL ATTEMPTS TO CONTACT HYUNDAI ASKING THAT THEY REPAIR MY VEHICLE. LISTED BELOW IS A PARTIAL LIST OF MY CORRESPONDENCE WITH THEM. 1/29/2020 CALLED HYUNDAI TALKED TO DANIELLE TO FILE INITIAL COMPLAINT, SHE INSTRUCTED ME TO TAKE THE VEHICLE TO MY LOCAL DEALER ( MIKE MILLER OF PEORIA, IL ) FOR AND INSPECTION. 2/3/2020 ' P.A. DENIED [XX] FROM HYUNDAI SAID THEY WILL DO A ONE TIME EXTENDED WARRANTY TO FIX THE DEFECT. BUT THEY DID NOT FIX THE VEHICLE. 2/5/2020 ' REQUEST THAT HYUNDAI CONSUMER AFFAIRS CALL ME. 2/6/2020 ' [XXX] (FROM THE WARRANTY TEAM) SAYS IT WILL COST $2,019 TO FIX 2/10/2020 ' FILED A COMPLAINT WITH THE BBB 2/13/2020 ' RESPONSE LETTER FROM BBB 2/25/2020 ' RESPONSE TO MY COMPLAINT LETTER TO HYUNDAI MOTOR AMERICA. ACKNOWLEDGING RECEIPT OF COMPLAINT. 4/7/2020 SENT A LETTER TO VP [XXX] COO ' NO RESPONSE. THIS LETTER MENTIONED THE CLASS ACTION LAWSUIT THAT WAS SETTLED ON MODEL YEARS 1999-2004 CASE #[XXX]. FILED IN THE STATE OF CALIFORNIA. 6/29/2020 RECEIVED A CALL FROM [XXX] (SERVICE MANAGER AT MIKE MILLER HYUNDAI) HE THREATENED TO HAVE MY VEHICLE TOWED AS ABANDONED. I OFFERED TO PAY 676.23 (HALF OF THE PARTS COST) TO HAVE THEM FIX THE VEHICLE. HE STATED HE WOULD SPEAK WITH CONSUMER AFFAIRS AND GET BACK TO ME. 7/6/2020 ' I CALLED [XXX] TO GET AN UPDATE. BECAUSE OF THE SERIOUS NATURE, I WOULD LIKE HYUNDAI TO COMPLETE THE REPAIR AT NO CHARGE. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

FRONT SUBFRAME SEVERE RUST THROUGHOUT THE FRAME

RUST HOLES THROUGH ENGINE CRADLE OR SUB FRAME. THIS CAR HAS ONLY 39,900 MILES ON IT AND WAS WELL MAINTAINED. WHILE GETTING OIL CHANGED THE MECHANIC SHOWED ME THE PROBLEM AND TOLD ME TO CONTACT THE HYUNDAI DEALER AND TELL THEM ABOUT IT. I CALLED AND THEY TOLD ME THERE WAS NOTHING THEY WOULD DO, I HAD TO PAY FOR THE REPAIRS.

I TOOK MY CAR TO MY MECHANIC TO CHANGE OIL ON 1/9/2018 AND HE DISCOVERED A BIG HOLE (BIGGER THAN THE FIST-SIZE) ON THE RIGHT FRONT OF THE SUBFRAME UNDERNEATH THE CAR DUE TO RUSTING AND SEVERE CORROSION (PLEASE SEE THE ATTACHED PICTURE FOR MORE DETAILS). THE MECHANIC TOLD ME THAT THIS IS A SERIOUS SAFETY ISSUE, WHICH IS NOT SUPPOSED TO HAPPEN. HE STRONGLY RECOMMENDED ME TO GO TO THE DEALER AND HAVE THIS FIXED AS SOON AS POSSIBLE. RIGHT AFTER THAT, I CALLED HYUNDAI CUSTOMER SERVICE AND THEY TOLD ME THAT MY CAR DOESN'T HAVE A WARRANTY AND IT IS NOT UNDER RECALL BASED ON THE VIN, SO THEY WILL NOT DO ANYTHING ABOUT IT. I GOT THE SAME ANSWER FROM THE DEALER AT HYUNDAI DAVIS IN NJ. I SEARCHED ONLINE AND FOUND 2 RECALLS ISSUED BY HYUNDAI FOR THE SAME PROBLEM. ONE STARTED IN 2009 WITH THE NHTSA RECALL ID # 09V124000 (INCLUDING 1999-2004 HYUNDAI SONATA) AND ANOTHER ONE IN 2013 WITH NHTSA CAMPAIGN # 13V354000 (INCLUDING 2006-2010 SONATA). HOWEVER, HYUNDAI CUSTOMER SERVICES CAN'T PROVIDE ANY EXPLANATIONS WHY 2005 SONATA IS NOT INCLUDED IN THE TWO RECALLS. ACCORDING TO THE NEWS ONLINE, 'THE RECALL, LIMITED TO AMERICA'S SO-CALLED "SALT BELT" STATES, IS CENTERED AROUND POTENTIALLY EXCESSIVE CORROSION OF THE FRONT SUB-FRAME DUE TO WINTER ROAD SALT APPLICATIONS. IF UNNOTICED, THE LOWER CONTROL ARM MAY SEPARATE FROM ITS MOUNT.' 'ROAD SALT AND WATER CAN ENTER PORTIONS OF THE REAR CROSSMEMBER, LEADING TO CORROSION OF THE CROSSMEMBER STEEL. THIS MAY LEAD TO DETACHMENT OF ONE OF THE REAR CONTROL ARMS. CONTROL ARM SEPARATION MAY SUDDENLY CHANGE THE REAR WHEEL ALIGNMENT, AFFECTING THE HANDLING OF THE VEHICLE, INCREASING THE RISK OF A CRASH.' IT IS NOT SAFE FOR ME TO DRIVE THE CAR, HOWEVER, CURRENTLY, I STILL HAVE TO DRIVE THE CAR ON HIGHWAY TO WORK ON A DAILY BASIS SINCE THIS IS THE ONLY CAR I HAVE.

THE ENGINE CRADLE AND BOTH REAR UPPER STRUT MOUNTS ARE CORRODED TO THE POINT THAT THE CAR IS UNSAFE TO DRIVE AND PRESENTS A SAFETY HAZARD TO ITS DRIVER, OCCUPANTS, AND OTHERS ON THE ROAD. IT WILL NOT PASS THE ANNUAL PENNSYLVANIA SAFETY INSPECTION. THE MECHANIC SHOWED ME (THE OWNER) AT LEAST ONE LARGE HOLE IN THE CRADLE (SILVER-DOLLAR SIZED) AS WELL AS LONG THREE-FINGER WIDE HOLES IN THE UPPER REAR STRUT MOUNTS. (THIS IS SIMILAR TO A PROBLEM THAT I ENCOUNTERED IN 2010 IN MY HYUNDAI ELANTRA (REAR SUSPENSION ONLY IN THAT CAR), REPORTED TO THE NTHSB AND SUBSEQUENTLY RECTIFIED BY HYUNDAI USA.) MOREOVER, THIS IS SIMILAR TO PROBLEMS CITED IN ROBERT D'ELIA V. HYUNDAI MOTOR COMPANY AND HYUNDAI MOTOR AMERICA AND RECTIFIED IN A SUBSEQUENT SETTLEMENT AND RECALL. THIS CONCERNS A CAR WITH 100XXX MILES ON THE ODOMETER. CAR WAS UNDERCOATED BY DEALERSHIP AT POS. DRIVEN EXCLUSIVELY IN A SALT-BELT STATE. N.B. - THE 2004 HYUNDAI SONATA SUB-FRAME IS IDENTICAL TO THE 2002 - 2004 SUBFRAMES.

LETTER FROM SENATOR PORTMAN ON BEHALF OF CONSTITUENT RE 2005 HYUNDAI SONATA SAFETY RECALL. *LD THE CONSUMER STATED FOR SEVERAL WEEKS, HIS DAUGHTER NOTICED SOME UNUSUAL VIBRATIONS AND NOISE WHILE DRIVING. AN INSPECTION REVEALED THE SUB-FRAME UNDER THE FRONT END ALSO CALLED THE CRADLE, WAS BADLY CORRODED TO THE EXTENT THAT SIGNIFICANT METAL IN THE SUB-FRAME WAS GONE;PERHAPS MORE THAN 50% GONE AT ONE LOCATION. THE CONSUMER WAS INFORMED A RECALL HAD BEEN ISSUED FOR THE VERY PROBLEM. HOWEVER, IT DIDN'T APPLY TO THE 2005 MODEL. HYUNDAI REFUSED TO COVER THE REPAIR, STATING THE MODEL WAS NOT COVERED. THE CONSUMER REFERENCED RECALL # 09V124000. *JB

DIRECT REPLY - LETTER FROM SENATOR BROWN INQUIRY ON BEHALF OF CONSTITUENT REGARDING HYUNDAI RECALL. *SMD 2005 HYUNDAI SONATA. THE CONSUMER STATED DURING A MAINTENANCE CHECK, THE MECHANIC FOUND THE SUB-FRAME UNDER THE FRONT END OF THE VEHICLE KNOWN AS THE ENGINE CRADLE WAS BADLY CORRODED TO THE EXTENT THAT SIGNIFICANT METAL IN THE SUB-FRAME WAS GONE; PERHAPS MORE THAN 50% GONE AT ON E LOCATION. APPARENTLY, THERE WAS NO RECALL FOR THE CONSUMERS MODEL YEAR. HOWEVER, A RECALL WAS ISSUED FOR OTHER YEARS. THE CONSUMER REFERENCED RECALL # 09V124000. *JB

FRONT CRADLE RUST OUT UNSAFE WILL NOT PASS INSPECTION. THE 2004S WERE RECALLED BUT NOT THE 2005S.

FAILED INSPECTION IN PART DUE TO FRONT SUBFRAME RUST THROUGH. CALLED HYUNDAI AND SPOKE TO A CLAIMS REP. BY THE NAME OF MIKE EXT.631677. MIKE TOLD ME THERE WERE RECALLS ON SONATAS UP TO 2004 FOR THIS PROBLEM, BUT NOT 2005. THE 2005 MODEL IS THE SAME MODEL AS 2004. THE MODEL YEAR DIDN'T CHANGE TILL 2006 SO WHY WAS 2005 EXCLUDED FROM THE RECALL? MY CAR HAS 115K MILES ON IT AND THE UNDERBODY IS ALWAYS WASHED DURING WINTER SEASONS. MIKE TOLD ME IT WASN'T UNDER WARRANTY, AND THAT HYUNDAI WOULD NOT BE ABLE TO DO ANYTHING FOR ME, TO CONTACT MY DEALERSHIP, MAYBE THEY WOULD DO SOMETHING. I HAVE A 1969 CAMARO AND THE SUBFRAME IS FINE. HOW IS IT THE A CAR 10 YEARS OLD HAS A BAD FRAME? HOPE YOU WILL BE ABLE TO HELP US.

I NOTICE THAT THERE IS A RECALL ON HYUNDAI SONATA'S FROM 2006 -2010 IN REGARDS TO RUST CONCERNS WITH REAR SUSPENSION. THIS WAS JUST DETECTED BY MY MECHANIC THAT THE ATTACHING POINT FOR THE CONTROL ARM HAS RUSTED AND BECAME SEPARATED FROM THE CROSSMEMBER. THE RESULT AND MY IMMEDIATE CONCERN WAS THE SUDDEN CHANGE IN VEHICLE HANDLING, A LOUD NOISE COMING FROM THE REAR TIRE WHEN I HIT A SMALL BUMP. I WAS WONDERING WHY THE 2005 SONATA ISN'T COVERED IN THIS RECALL?

ACCORDING TO MECHANIC THE UPPER CONTROL ARM REAR PASSENGER SIDE IS RUSTED AND DETACHED.

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING 10 MPH, THE FRONT DRIVER'S SIDE WHEEL PARTIALLY SEPARATED FROM THE SUSPENSION SYSTEM. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS WHERE IT WAS ADVISED THAT THE SUB FRAME WAS RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED AND MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 135,000. *TR